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E-Axle Test Bench

E-Axle Test Bench

Electric drives are at the heart of both battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs), As manufacturers face growing demands for industrialization and increased production volumes, Our comprehensive solutions support every phase of the project lifecycle—from concept development to implementation and operation. These solutions are designed to cater to a wide range of vehicles, including passenger cars, as well as light and heavy commercial vehicles.

The drive system of an electric vehicle (EV) comprises several key components. Central to this is the e-axle or electric drive unit (EDU), which integrates the electric motor, transmission, and inverter. While we provide dedicated testing solutions for each individual component, it is equally important to test the fully assembled e-axle to identify and address potential assembly-related defects, such as Noise, Vibration, Harshness (NVH) and EMC/EMI testing, which significantly impacts driver and passenger satisfaction and ensure the safety of the vehicle

The system can be 3ways/1 input+2 output, 4 ways, 5 ways, which can be integrated as powertrain testing solution
E-Axle Test Bench​

The comprehensive 3-in-1 electric axle test benches for both light-duty and heavy-duty vehicles address crucial factors such as performance, durability, noise, vibration, and harshness (NVH), as well as electromagnetic compatibility (EMC). These advanced test benches are designed to support manufacturers in developing sustainable electric drive systems that meet the highest standards of performance and quality in the automotive industry. By thoroughly assessing these key areas, manufacturers can ensure their electric axles are reliable, efficient, and capable of delivering optimal performance under real-world conditions.

E-Axle

Light-duty electric axle

We offer a customized solution for the development and validation of light-duty e-axles, whether for single or dual motor configurations. With shortest lead times, manufacturers can quickly begin lifecycle and thermal endurance testing, as well as detailed electrical, mechanical, and thermal property analysis. This advanced test system enables precise performance and functional testing at speeds up to 20,000 rpm and power levels up to 400 kW, supported by a direct drive dynamometer, flexible multi-channel cooling conditioning, and a climatic chamber for comprehensive environmental simulation.

The light-duty electric axle test bench is a customizable solution tailored to the specific needs of manufacturers, whether they are working with single or dual motor configurations. This flexibility enables engineers to develop and validate various units under test (UUTs) efficiently. Equipped with advanced instrumentation and testing capabilities, the test bench allows for comprehensive assessments of the electric axle’s performance characteristics. Its design ensures quick adaptation to different configurations and testing scenarios, making it easier for manufacturers to optimize their electric drive systems for a wide range of applications.

A key advantage of the light-duty electric axle test bench is its rapid delivery time, which allows clients to perform essential in-service lifetime and thermal endurance testing with minimal delay. This expedited timeline is especially critical for manufacturers aiming to bring their products to market quickly while ensuring compliance with rigorous industry standards. The test bench provides valuable insights into mechanical, electrical, and thermal properties, helping engineers identify potential issues early in the development process. By conducting these thorough evaluations, manufacturers can refine their designs, enhance durability, and improve overall performance, ultimately leading to the successful deployment of high-quality electric drive systems in light-duty vehicles.

Heavy-duty electric axle

The Heavy Duty test system is a standardized solution designed for the development and validation of e-axles in commercial vehicles, specifically tailored for trucks and buses. It enables comprehensive lifecycle testing under realistic, vehicle-like conditions. The system supports precise performance and functional testing, with capabilities of up to 20,000 rpm and 400 kW. Equipped with a direct-drive dynamometer, flexible multi-channel cooling conditioning, and a climatic chamber for environmental simulations, it ensures that the e-axles perform optimally across various operating conditions.

The X way-in-1 electric axle test bench is engineered to meet the temperature and service lifespan certification requirements for electric drive units. This system is optimized for efficient testing, allowing seamless integration of duty cycles with pre-configured standardized cycles for temperature aging and lifespan certification during the operation of the Unit Under Test (UUT). This flexibility ensures that manufacturers can thoroughly evaluate the performance and durabilityof their electric drive systems, resulting in more robust and reliable products.

Electric axle test bench for NVH/EMC

The electric axle test bench for NVH is designed to redefine silence, comfort, and overall performance in both light-duty and heavy-duty e-axle solutions. With exceptionally low operating noise levels, it ensures superior NVH performance, making it ideal for the development of quiet and smooth electric powertrains. The system also features semi-automatic track width and wheelbase adjustments, which streamline high-end NVH development, providing engineers with the flexibility to optimize performance easily.

This innovative solution sets new industry standards for NVH engineering in both current and future e-powertrains, ensuring that electric axles deliver not only optimal performance but also maximum user comfort and satisfaction. It is designed to meet the demands of a wide range of mobility applications, enhancing the driving experience and making it more enjoyable for all users.

To measure the electromagnetic compatibility (EMC) of e-drive systems and assess both their emissions and immunity to interference, specialized EMC test systems are essential. We offer precise EMC measurements and testing in accordance with the CISPR 25 standard, ensuring that your systems meet the most stringent industry regulations.

This solution allows for effective evaluation of both the emissions and immunity of your e-axle components, guaranteeing the reliability and compliance of electric drive systems. By using this testing approach, manufacturers can ensure their systems are ready for future mobility applications, offering both performance and regulatory compliance.

Applications of Electric Drive Unit and Electric Axle Test Bench:

  1. Service Lifespan Testing

    • Assessing the durability and longevity of electric drive systems and axles under simulated real-world conditions.

  2. High-Speed and Torque Testing

    • Evaluating performance at both high speeds and high torque levels to ensure optimal functionality under demanding operating conditions.

  3. Torque Differential and Speed Difference Testing

    • Measuring and analyzing variations in torque and speed across the electric axle or drive unit to ensure smooth operation and performance balance.

  4. Peak Power Testing

    • Assessing the system’s ability to handle short bursts of peak power, ensuring the e-drive can deliver maximum output when required.

  5. Electrical to Mechanical Power Efficiency Testing

    • Analyzing the conversion efficiency from electrical to mechanical power, helping to identify areas for improvement in energy use.

  6. Torque Interface to Electric Drive in No-Throttle Test

    • Evaluating torque response and control when the throttle is not engaged, simulating idle or coasting conditions.

  7. xCU Interface to E-Drive for Throttle Test

    • Testing the responsiveness and control of the e-drive when interfaced with the throttle control unit (xCU), simulating real-world acceleration and deceleration.

  8. Driving Cycle Testing

    • Simulating real-world driving conditions by using predefined driving cycles to assess the overall performance and efficiency of the electric drive unit.

  9. Vibration Analysis

    • Analyzing vibrations generated during operation to identify and mitigate issues related to mechanical resonance, efficiency losses, or NVH (Noise, Vibration, and Harshness) concerns.

Thermal Examinations:

  1. Cooling System Stability Test

    • Testing the stability and effectiveness of the cooling system to ensure that the electric drive unit maintains optimal operating temperature.

  2. High-Temperature Operating Endurance (HTOE)

    • Assessing the electric drive’s ability to operate reliably under high-temperature conditions over extended periods.

  3. Powered Thermal Cycle Endurance (PTCE)

    • Evaluating the system’s ability to withstand repeated thermal cycles, simulating various temperature extremes that may occur during operation.

These testing capabilities ensure that electric drive units and axles are thoroughly validated for performance, reliability, and efficiency, preparing them for integration into next-generation mobility solutions.

 
AC dynamometer/AC Dyno​ Test Bench

AC dynamometer/AC Dyno

An AC dynamometer is a crucial piece of performance testing equipment used in motor manufacturing and product development. It simulates and regulates the motor’s load to evaluate its performance characteristics. The AC power dynamometer system consists of a test motor and a four-quadrant frequency conversion unit. This advanced frequency conversion technology enables precise control in all four quadrants, allowing the dynamometer to function as a test load for the motor under various operating conditions.

Econo Test offers a comprehensive range of dynamometers designed for diverse testing applications, from internal combustion engines and their components to electric and hybrid vehicle systems. Our solutions cater to small electric tools, large electric motors, off-road diesel engines, marine engines, complete drivetrains, integrated e-drive systems, electric axles, and core electrification components like EV gearboxes.

AC dynamometer

Additionally, our AC dynamometers are engineered to accommodate a wide range of engine types, from compact off-road engines to high-power industrial engines, with power capacities spanning from 10 kW to 2,000 kW. They are ideally suited for engine certification, calibration, research and development, and end-of-line testing, meeting the rigorous demands of heavy-duty applications.

Test Scope:

No-load test, rated test, peak torque, peak speed, durability test, temperature rise test, torque fluctuation, speed fluctuation, back EMF test, T-N curve test, motor start-up test, frequency response bandwidth, driver performance test, efficiency map (MAP), forward/reverse speed difference rate, electrical time constant, torque control response time, speed control response time, dynamic position tracking error, braking torque test, speed regulation rate, d-q axis inductance, locked rotor test, efficiency test, overspeed, thermal resistance, inertia simulation, electromechanical time constant.

Asynchronous dynamometer (induction dynamometer)/PM dynamometer (permanent magnet synchronous dynamometer)

E-Axle

The AC dynamometer used for engine testing consists of an asynchronous AC induction dynamometer paired with a 4Q-frequency converter cabinet, providing a specialized solution for evaluating dynamic and transient engine applications with high precision. When coupled with additional accessories, this system ensures professional-grade testing capabilities, making it ideal for both current and future generations of combustion and hybrid engines.

This dynamometer series strikes an ideal balance between total cost of ownership and performance. By combining reliable, proven components with innovative designs, it offers excellent power coverage across various performance classes. This means fewer types of test equipment are required, resulting in greater flexibility and cost-efficiency. Its advanced torque-to-inertia ratio makes it perfectly suited for testing the latest engine technologies.

The frequency converter cabinet includes a high-speed interface to the controller, enabling rapid torque changes that simulate real vehicle load transitions. High-precision torque and speed monitoring ensure repeatable and reliable load conditions, essential for accurate engine testing. This design supports continuous operation, guaranteeing optimal test equipment efficiency and allowing for quick progress in engine development.

AC dynamometer-Engine testing

A key feature of this AC dynamometer series is its exceptional range of speed and torque capabilities. Each unit is designed to handle a wide array of testing scenarios, which becomes even more effective when paired with a gearbox. This versatility enables users to achieve both high nominal torque and the required speeds for comprehensive testing, making it ideal for applications such as gearbox performance evaluation, drivetrain efficiency analysis, and durability testing. Its flexibility makes the AC dynamometer series an essential tool for engineers and researchers across various industries.

Furthermore, this AC dynamometer is especially suited for testing axles and drivetrains in heavy-duty machinery applications. It is capable of supporting tests for a wide range of equipment, including tractors, graders, bulldozers, compactors, excavators, articulated dump trucks, and loaders. With its powerful torque and speed capabilities, this dynamometer series ensures that heavy machinery can be rigorously tested under real-world conditions, helping to enhance performance, durability, and overall reliability in the field.

Engine testing

How to Choose a AC dynamometer Test Bench:

When choosing a AC dynamometer test bench, consider the following factors:

  • Motor Type: Ensure the test bench supports the type of motor you plan to test (e.g., AC, DC, BLDC, servo).
  • Test Requirements: Identify the parameters you need to measure (e.g., torque, speed, power, efficiency).
  • Speed Range: Choose a test bench that can handle the speed range of the motor you’re testing.
  • Load Capacity: Ensure the test bench can simulate the necessary loads for your motor’s application.
  • Accuracy and Precision: Select a test bench with accurate measurement instruments and high precision, especially for motors in critical applications like aerospace or automotive.
Motor test bench

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Types Of Electric Motors

A motor test bench can be used to test various types of electric motors, each with its own set of testing requirements. The primary types of motors that can be tested on these benches include:

1. AC Motors (Alternating Current Motors):

  • Squirrel Cage Induction Motors: The most common type of AC motor used in industrial applications.
  • Slip Ring Induction Motors: Used for higher torque applications, where the rotor is connected to external resistors.
  • Synchronous Motors: Used in applications requiring constant speed, such as in power plants.
  • Single-phase AC Motors: Typically used in residential appliances and small machinery.
  • Three-phase AC Motors: Widely used in industrial machinery and large-scale applications due to their efficiency.

Test Bench Capabilities: AC motor test benches can measure parameters like power, torque, speed, efficiency, power factor, and current/voltage characteristics under various loads and conditions.

2. DC Motors (Direct Current Motors):

  • Brushed DC Motors: Commonly used in small devices, toys, and robotics.
  • Brushless DC Motors (BLDC): Used in applications that require higher efficiency, such as in electric vehicles and drones.
  • Permanent Magnet DC Motors: These motors use permanent magnets instead of electromagnets for the rotor and are common in small appliances and machinery.
  • Series-wound, Shunt-wound, and Compound-wound DC Motors: Various configurations, each suited to different types of load applications.

Test Bench Capabilities: DC motor test benches can measure current, voltage, speed, torque, power, and efficiency, with specific testing methods for both brushed and brushless configurations.

3. High-Speed Motors:

  • Turbochargers, Air Compressors, and High-speed industrial motors: Used in applications requiring high-speed rotations, such as aviation or high-precision industrial machinery.

Test Bench Capabilities: High-speed motor test benches are designed to measure the motor’s performance at high rotational speeds, including vibration analysis, noise levels, and efficiency at varying speeds.

4. Stepper Motors:

  • Permanent Magnet Stepper Motors: Used in precise position control applications such as CNC machines, printers, and robotics.
  • Hybrid Stepper Motors: Combine the features of permanent magnet stepper motors and variable reluctance motors.
  • Variable Reluctance Stepper Motors: Often used in automotive and industrial applications.

Test Bench Capabilities: These test benches are used to test the accuracy, torque, speed, and precision of stepper motors, ensuring they meet specific requirements for movement control.

5. Synchronous Motors (AC and DC):

  • Permanent Magnet Synchronous Motors (PMSM): Often used in electric vehicles (EVs) and industrial applications requiring high efficiency.
  • Reluctance Motors: Used for specialized applications where the rotor does not require windings or magnets.

Test Bench Capabilities: Synchronous motors require precise control of speed and torque, which is typically tested under varying load conditions to verify stability and efficiency.

6. Universal Motors:

  • These motors can run on either AC or DC power. They are typically found in portable power tools and small appliances.

Test Bench Capabilities: A motor test bench for universal motors will test performance under both AC and DC inputs, checking for speed, torque, and power consumption.

7. Servo Motors:

  • AC Servo Motors: Used for precise control applications such as robotics, CNC machinery, and aerospace applications.
  • DC Servo Motors: Used in precise control systems, often for feedback control loops in various automation applications.

Test Bench Capabilities: Servo motor test benches allow testing of dynamic response, position control, speed control, and torque output under controlled loads, providing data on the motor’s performance in closed-loop systems.

 

Dynamometer
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Dynamometer test solution

Magnetic Powder Dynamometer

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