Commercial Vehicle & Automotive
Our team here at DSI Innovations understands the high-stakes demands of vehicle and component manufacturing, where shifting regulations, evolving technologies, and global pressures demand a quick, versatile response. DSI’s game changing automation solutions go well beyond typical integration – offering customized equipment, testing systems, software, and production optimization tools all tailored to keep your operations compliant, competitive, and agile.
With experience in both component and cell-based manufacturing, and assets like our regenerative energy surface dynamometer with full ABS capacity, we’re equipped to deliver turnkey support or seamlessly augment your team. Your success is our mission, so let’s partner up to help you keep your production in sync with an ever-changing vehicle industry, and take your business to much higher levels!
Our Commercial Vehicle & Automotive Capabilities
Dynamometer Systems & Upgrades
- Legacy System Modernization: Upgrading legacy dyno control systems—regardless of manufacturer—with modern automation platforms to improve reliability, performance, and long-term serviceability
- Drive System Upgrades: Converting fixed-speed dynamometers to variable-speed systems using advanced VFD technology to improve test flexibility and energy efficiency.
- Equipment Evaluation & Consulting: Assessing existing dynamometer infrastructure for lifecycle status, performance accuracy, and upgrade potential based on current industry standards.
- ABS Integration Capabilities: Offering DSI’s ABS simulation systems as retrofits to compatible third-party dynos, enabling accurate brake testing without requiring full system replacement..
- Cross-Compatible Dyno Software: Providing DSI’s control software with support for a wide range of OEM dynamometers, delivering enhanced test automation and centralized control..
- Automated Hold-Down Systems: Designing and integrating secure hold-down systems for light-frame vehicles to ensure safety and repeatability during surface dyno testing.
- Optimized Software Retrofits: Replacing underperforming software on legacy dynos with DSI’s advanced control platform to unlock precision, repeatability, and reporting enhancements.
- Regenerative Energy Reclaim: Integrating energy recovery solutions with dynamometers or plant-wide systems to capture and reuse excess power, reducing operational costs and environmental impact.
DynaMack™ Dynamometers
- Multi-Axle Surface Testing: Supporting both single-axle and multi-axle test configurations with the ability to test axles individually or simultaneously—ideal for flexibility in production and development environments.
- Regenerative Energy Reclaim: Offering advanced regenerative energy systems that return excess power to the facility or grid—often producing more energy than consumed, reducing operating costs and environmental impact.
- Integrated ABS Testing: Enabling anti-lock braking system validation directly on the dyno platform without standalone equipment—streamlining final validation workflows and increasing test throughput.
- High-Speed Brake Testing: Utilizing specially engineered roller systems to safely simulate high-speed road conditions for accurate brake performance testing.
- Automated Vehicle Centering: Providing optional vehicle centering systems to improve operator safety, streamline setup, and increase test repeatability.
- Comprehensive Test Capabilities: Supporting a wide range of test options including braking, horsepower, parasitic loss, fluid levels, traction control, cruise control, environmental monitoring, dashboard validation, engine and trailer brake tests, and axle weight measurement.
- Flexible Test Applications: Configurable for end-of-line testing, offline validation, R&D, environmental testing, and safety evaluations—offering units capable of surface, shaft, and axle testing within a single platform.
- Advanced Test Software: Enabling over 300 test scenarios with integrated traceability—linking test results to specific work cells and triggering alerts on component-level failures.
- Universal Vehicle Communication Support: Offering proprietary communication drivers and full support for SAE standards, while allowing integration with customer-specific protocols and data interfaces.
- Turnkey Installations & GC Services: Providing complete system design, installation, and general contracting support to deliver fully integrated and ready-to-run test solutions.
- Custom Dynamometer Designs: Engineering custom dyno solutions to meet unique requirements for specialty vehicles, emerging technologies, or space-constrained installations.
Fluid Filled Systems
- Modular System Architecture: Compact, modular design allows system components to be configured like building blocks—enabling fast customization for various plant layouts and fill requirements.
- Flexible Mounting Options: Available in floor-mounted, overhead track, or tank-farm configurations to fit seamlessly into any production footprint.
- Space-Saving Design: Engineered with a minimal footprint and optional powered self-stacking tanks to maximize usable floor space without compromising capacity.
- Quick-Swap Maintenance Features: Designed for high uptime—operators can replace pumps or hose reels in under 3 minutes using DSI’s tool-free quick-clamp mechanism.
- Dyno Software Integration: Seamlessly connects with DSI’s dynamometer software platform for real-time tracking of pre- and post-dyno fluid fill operations.
- Batch Traceability & Vehicle File Integration: Attaches VIN-based fill data—batch ID, volume, flow rate, and timestamps—to paper or digital vehicle records for complete traceability.
Mobile Test Carts
- Chassis Leak Testing: Performing mobile air line leak detection with real-time reporting to ensure system integrity before final assembly.
- Axle Speed Sensor Validation: Verifying axle-mounted speed sensors for correct functionality and signal accuracy prior to vehicle rollout.
- Dashboard Systems Testing: Connecting via CAN to confirm dashboard gauge, switch, and light operations before installation into the vehicle.
- Engine ECU Verification: Conducting pre-installation ECU checks including programming, diagnostics, and fault code validation.
- Flexible Deployment: Compact, wheeled platforms designed for mobility across workstations or line-side applications—ideal for both production and rework zones.
CV Parts Manufacturing Automation
- Press Control Systems: Delivering packaged press control solutions for precision forming, stamping, and punching applications—enhancing repeatability and safety.
- Automated Press Feeding: Providing customized press feed systems to reduce manual labor, improve throughput, and optimize material handling.
- Legacy System Modernization: Upgrading obsolete control systems with modern automation platforms to boost performance, safety, and supportability.
- Robotic Integration: Designing and implementing robotic solutions for tasks that require flexibility, precision, or custom handling beyond standard packages.
- Custom Motion Systems: Offering purpose-built motion platforms for part movement, alignment, or transfer—when a robot isn’t the right fit.
- Vision & Inspection Systems: Deploying multi-platform vision solutions for dimensional inspection, product verification, thermal imaging, and surface defect detection.
- Work Cell Safety Solutions: Engineering custom safety systems, performing risk assessments, and upgrading existing cells to meet compliance and protect personnel.
- Drive System Upgrades: Providing expert services for drive modernization, including variable speed drives and motor control systems for presses, conveyors, and auxiliary equipment.
- Industrial Oven Control: Automating oven systems with burner management, gas safety integration, moisture tracking, and process trending for consistent heat treatment.
- Utility System Automation: Implementing automation for boilers, feedwater systems, and auxiliary utilities to increase energy efficiency and reduce downtime.
- Wastewater Treatment Controls: Providing turnkey control solutions for clarifiers, sludge pumping, filtration, chemical dosing, and sampling in manufacturing support systems.
SCADA & Data Systems
- Dyno Software Integration: DSI’s dynamometer software acts as the foundation of a plant-wide reporting system—tracking test results, linking to electronic vehicle records, and enabling real-time decision-making.
- Sales Order Database Connectivity: Ties vehicle testing and validation directly to upstream order entry systems, confirming build specifications at the start of production.
- VIN Parameter Retrieval: Pulls vehicle-specific data from local or corporate data centers to configure tests, validate components, and guide material kitting for each unit.
- CMMS Integration: Providing manufacturing-focused CMMS platforms that support preventive maintenance, utility equipment tracking, and integrated service scheduling.
- Preventive & Predictive Maintenance Systems: Offering traditional PM schedules alongside analytics-driven monitoring tools to proactively detect issues before they impact operations.
- Building Automation Compatibility: Expanding SCADA beyond the production floor to include facility HVAC, lighting, access control, and utility systems under one cohesive platform.
- Condition-Based Monitoring: Deploying systems to track vibration, temperature, oil quality, environmental conditions, and VFD performance for early fault detection.
- Real-Time Location Systems (RTLS): Locating vehicles in large plant lots or staging areas with high-accuracy tracking tools to eliminate delays and misrouting.
- Material Kitting Integration: Linking logistics to the vehicle build order, ensuring the right parts and tools are staged at the right time for every unit.
- Post-Delivery Tracking (Turn & Sell): Extending visibility beyond production by tracking units after they leave the facility—capturing data for customer support, warranty, or performance analytics.
Upgrades, Retrofits & Migrations
- Legacy Migrations & Obsolescence: Removal of end-of-life hardware and unsupported systems to prevent downtime risks, ensure replacement parts availability, and secure long-term reliability through modern, vendor-supported solutions.
- Hardware & Software Upgrades: Incorporating new controllers, drives, sensors, or automation software to boost system reliability, integrate modern features, and future-proof operations.
- Retrofits & Expansions: Enhancing or reconfiguring existing equipment and systems to meet evolving production demands, address obsolescence, and capitalize on new market opportunities—all while managing costs and downtime through planned rollouts.
- Parallel Testing & Commissioning: Running new solutions in tandem with existing setups to minimize operational interruptions and verify functionality before full cutover.
- Hardware & Software Standardization: Unifying multiple control platforms, operating versions, and communication protocols to simplify maintenance, reduce training overhead, and streamline spare parts management.
- Phased Implementation Strategies: Scheduling major updates—mechanical, electrical, or software-related—over planned outages or staggered deployments, ensuring production continuity and optimized resource usage.
- Post-Upgrade Support & Optimization: Providing ongoing support after modernization, including system tuning, operator training, and performance reviews to ensure a smooth transition and long-term success.
Maintenance & Support Services
- Preventive Maintenance Programs
Regularly scheduled inspections and servicing to minimize downtime and extend equipment lifespan.
- Contract Preventive Maintenance: Offering scheduled maintenance services for DSI systems to reduce downtime and extend equipment life.
- System Optimization Studies: Providing expert evaluations to identify performance gaps and recommend improvements—bringing a fresh set of eyes to boost reliability and efficiency.
- Turnkey Support Packages: Delivering complete service coverage, including unlimited licensing options, to ensure long-term system maintainability and performance.
- Full-Service Dyno Support: Supporting DSI dynamometers with preventive, predictive, and emergency maintenance—tailored to your operational schedule.
- Calibration Services: Providing annual NIST-traceable calibration services to ensure measurement accuracy and compliance across critical test systems.
- 24/7 Technical Support & Emergency Response (with Support Contract)
Round-the-clock assistance to address urgent issues, available to clients who opt for a support contract.
- Field Services
Rapid dispatch of technicians to diagnose equipment issues, perform repairs, and restore functionality—minimizing disruption and downtime.
- Remote Monitoring & Troubleshooting
Real-time tracking of system performance to detect and resolve potential issues before they escalate.
- Staff Augmentation
Access to skilled professionals to fill short-term or specialized staffing needs for ongoing or complex projects.
- Software & System Upgrades
Regular updates to maintain optimal performance, ensure compatibility, and address emerging security concerns.
- Employee Training & Knowledge Transfer
Comprehensive support for in-house teams, covering best practices and hands-on training.
- Compliance & Safety Support
Guidance on meeting regulatory requirements and maintaining best practices for safe operation.
- Lifecycle & Asset Management
Proactive planning for equipment upgrades and replacements to optimize total cost of ownership.
Featured Projects
Case Study
REVITALIZING PERFORMANCE: Modernizing Dyno Systems for Smarter Testing
Case Study
DRIVING INNOVATION: Next-Gen Dynamometer Systems
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