Dainese experiences
Dainese is a global leader in the development of protective clothing for motorcyclists and racing drivers. With its D-Air® technology, the company has developed an intelligent airbag system for racing suits and streetwear based on sensors, algorithms and electronics.
"I never thought I’d see a colleague take the test system home with them – that’s truly groundbreaking! It even fits in a backpack." Nicolò Bargellesi – Algorithm and AI engineer for models and solutions for airbags and electronics – Dainese
Experiences
Our problem
We develop intelligent airbag systems for racing suits and streetwear. Our key challenges:
- Reliably validating algorithms so that the airbag deploys at the right moment – even with defective sensors or low battery power.
- Preventing false deployments (misfires) while ensuring that the system functions correctly in all relevant scenarios.
- Use a large amount of data from MotoGP races and everyday situations without having to carry out time-consuming manual tests.
- Safety certification of the end product, which requires comprehensive test coverage.
The solution
With PROTOS’ miniHIL, we were able to:
- Test algorithms continuously and automatically – even during development.
- Simulate all relevant scenarios: crashes, normal operation, malfunctions, low battery conditions.
- Perform regression tests after every software change – quickly, repeatably, without hardware load.
- Import historical data from over 15 years of MotoGP and road use in real time.
- Perform certification-relevant safety checks without endangering physical systems.
Before miniHIL, in-depth testing involved a great deal of manual effort – with miniHIL, it is now quick, repeatable and safe.
"The miniHIL gave us certainty – the product is delivered within 24 hours – no problem! Better than human/manual testing." Marco Maculan – Firmware Engineer
Projekt 1: Smart Air & Electronics of Racing Suits (D-Air® Racing)
Description:
- Further development of Racing Suits, examples: Products
- Redesign and validation of airbag algorithms
- Data collection from MotoGP races since 2007 (several terabytes, reduced to relevant cases)
- Use of real data for miniHIL tests in real time
- Test scenarios: normal driving conditions, crash situations, error scenarios
Technical focus:
- Trigger logic of the airbag (correct timing of activation, even with defective sensors or low battery)
- Simulation of defective systems with miniHIL
- Validation: no misfires, correct activation in all situations
- Tests of states such as ‘armed’, error status, low battery charge
Safety is a key factor for us – testing with miniHIL is essential to ensure certification of the end product.
Project 2: Smart D-Air (older version) / Smart Jacket
Description:
- Validation of airbag activation for road products
- Integration of automotive airbag technology (gas generator)
- Testing with GPS sensor, acceleration and orientation sensors
- Testing of arming logic and error scenarios (low battery, error states, false triggering)
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