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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, mechanisch, and thermal property analysis. This advanced test system enables precise performance and functional testing at speeds up to 20,000 U/min 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, elektrisch, 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 U/min Und 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 Testbank 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 Und 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 Emissionen Und 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 Emissionen Und Immunität of your e-axle components, guaranteeing the Zuverlässigkeit Und 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, Zuverlässigkeit, Und Effizienz, preparing them for integration into next-generation mobility solutions.

Service und Support

Reasons for the high temperature of high-speed shaft bearings：

Für Hochgeschwindigkeitswickeln, high-speed bearings are generally used. The alarm temperature of the high-speed axis generally does not exceed 75℃, and it is recommended to keep it within 60℃ for long-term operation. High bearing temperature is generally caused by the following reasons:
(1) The coaxiality of the shaft system has deteriorated
(2) The lubrication state of the bearing has deteriorated, and grease needs to be added or the bearing needs to be replaced
(3) If there is a floating end bearing in the shaft system, the floating function of the floating end may fail
(4) Bearings wear out due to prolonged use
(5) For bearings that have been used for a period of time, there is a general relationship between temperature and vibration, and vibration will cause the temperature to rise. The fault of the bearing can be judged from the spectrogram.

Causes of high vibration value of high-speed rotating machinery：

For high-speed rotating machinery, there are generally several reasons for excessive vibration values:
(1) The shafting coaxiality is poor. Generally, the rotation speed exceeds 8000rpm, and the coaxiality needs to reach 0.02mm~0.03mm
(2) There are soft feet in the drive motor
(3) Poor shaft dynamic balance
(4) Resonance occurred in some frequency bands
(5) The bearings and other supporting parts of the shaft system are malfunctioning


High-speed motor inverter selection：

For high-speed motors, when the IGBT switching frequency of the inverter is increased, the output harmonics will increase. Because the reactance of the high-speed permanent magnet synchronous motor is small, the harmonics will cause the motor to generate serious heat. The magnet will demagnetize, and the control will be unstable, so the output harmonic of the inverter needs to be weakened.</span><br><span> The switching frequency of the drive is generally selected to be 12-15 times the maximum operating frequency of the motor. The higher the motor frequency, the higher the corresponding ratio of the required switching frequency.

Selection

Dynamometer selection method：
According to different motor models, there are two types of S1 curve (continuous duty system) in the operating stage from static to rated operating point: using the maximum torque allowed in temperature and using constant torque (usually using constant torque). The power will increase with the speed according to the torque type. This is followed by a period of constant power, during which field weakening occurs. The field weakening range is limited by the voltage limit value. The overload capacity is generally implemented according to the S6 (40%) work system.

Selection method

The selection of dynamometer needs to consider the following factors:

For the rated power, rated speed, maximum speed, overload factor, usw. of the tested motor, it is generally required that the S1 curve of the dynamometer can cover the peak curve of the tested motor. If in order to save costs, or the dynamometer selection is difficult, you can also consider using the dynamometer’s S6 curve to envelope the peak curve of the tested motor, but you must consider that the dynamometer’s overload time cannot exceed the design requirements.
Taizhou Guangzhong Electrical Equipment Co,.Ltd

The guidance for Selecting Motor Testing System:

1.According to the tested motor type, parameters, and test function requirements, comprehensively consider the selection of a series of dynamometers (GZC series hysteresis dynamometer, GZF series magnetic particle dynamometer, GZW series eddy current dynamometer, GZDL series electric dynamometer machine).

2.Select a certain range dynamometer according to the parameters of the motor under test
1). The speed of the motor to be tested cannot be greater than the maximum speed of the dynamometer.

2). The rated torque of the motor under test should be within 10%-100% of the full scale.

3). If temperature rise test is required, the rated power of the motor under test cannot be greater than the continuous operating power of the dynamometer.

3.Choose a suitable test system according to the type of motor under test and test function requirements to form a complete dynamometer system.

If it is difficult to choose, you can provide us with the rated parameters and peak parameters of the motor (you can also send us samples directly), and we will provide a more reasonable solution.

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