Powertrain Test Benches

For the targeted testing of individual components or subsystems of electric powertrains, we offer our customers modular single-axis test benches that can be flexibly adapted to different test tasks. The systems enable highly dynamic tests with variably definable system boundaries – from e-motor via transmission stages and differentials to power electronics, combined with optionally provided universal components.

In addition to functional and efficiency measurements, material compatibility, thermal behaviour, energy consumption as well as wear and durability can be investigated in detail. Benchmarking, efficiency analyses and friction power measurements complement the test spectrum.

Complete temperature conditioning, real-time data acquisition and easy integration into subsequent tests on the vehicle test benches ensure a seamless transition within the testing chain at all times.

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Range of services

  • Efficiency measurements & efficiency analyses
    Electrical and mechanical in the overall system
  • Torque and power tests
    Dynamic load tests under real conditions
  • Functional tests & endurance runs
    Load and long-term testing of individual units
  • Temperature & cooling performance tests
    Investigation of thermal performance
  • Friction power measurements
    Analysis of power losses due to friction
  • Wear & durability data
    Long-term behaviour under continuous load
  • Material compatibility
    Compatibility with operating fluids and materials
  • Oil foaming
    Analysis of lubrication behaviour in operation
  • Energy consumption & range
    Efficiency assessment of electrical systems
  • Benchmarking
    Comparative measurements with reference systems

Equipment

  • Modular test benches – freely combinable e-motor, transmission and electronic components
  • Drive machines with 455 kW rated power (800 Nm rated torque, 10,000 rpm maximum speed)
  • Maximum speed can be increased to 20,000 rpm with an intermediate transmission
  • Output machines with 220 kW rated power each (3,200 Nm rated torque, 3,000 rpm maximum speed), overload capable up to 330 kW and 4,800 Nm
  • Measuring room for the mechanical & visual evaluation of wear and damage
  • Physico-chemical analysis laboratories for used oil or coolant/lubricant analysis
  • AVL Puma Open 2 automation
  • AVL X-ion high-voltage measurement technology
  • Extension of the measurement scope through analogue sensors for pressures, temperatures, electrical currents and voltages
  • Dual-circuit coolant conditioning (-40 to +120 °C)
  • Climate hood for e-motor and transmission (-40 to +120 °C, 5 K/min temperature change rate)
  • Battery power simulation with 400 kW, 1000 V maximum voltage and 1000 A maximum current
  • Universal drive, rated power 400 kW, maximum output voltage DC 1,200 V, max output current DC 800 A
  • Low voltage supply for control units and residual bus simulation
  • In-line gas content measurement technology