Challenge details:

The Roller Brake Test (RBT) is a critical end-of-line validation process used to assess braking performance, speed test, features test and other vehicle functions in commercial vehicles before dispatch. During the test cycle, an operator remains inside testing area to test the vehicle for approximately 12-15 minutes and continuously following instructions displayed on a front screen or LED panel. The operator is required to perform multiple driver-dependent actions as per testing cycle, including engine start/stop, clutch operation, gear shifting, accelerator control, service brake application, parking brake engagement, steering wheel movement or correction, and other vehicle maneuvers necessary to complete the prescribed test sequence.

This manual intervention requires the operator to perform multiple driving-related actions and repeatedly enter and exit vehicles of different configurations, including cabin and cab-less variants. As a result, the operator is exposed to exhaust fumes, noise, vibration, and heat, while the repetitive nature of the activity can contribute to fatigue during prolonged operations.

The core challenge is to automate the driver-dependent activities involved in the RBT process for manual-transmission commercial vehicles. The solution should be capable of executing predefined test sequences by automatically actuating the clutch, accelerator, service brake, parking brake, steering system, engine controls, and gear-shifting mechanisms, while ensuring safe, repeatable, and reliable vehicle operation throughout the test cycle. The system should integrate seamlessly with the existing RBT infrastructure, enhance operator safety, improve test repeatability, and reduce dependence on direct human intervention without compromising test accuracy or throughput.