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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 avec 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 efficacité, preparing them for integration into next-generation mobility solutions.

Powertrain/Hub-coupled powertrain Test Bench

Powertrain/Hub-coupled powertrain Test Bench

Powertrain systems primarily relied on transmission concepts before, such as manual, automatic, and dual-clutch transmissions for 2WD and 4WD vehicles. However, with the transition to fully electrified propulsion systems, the modern one has undergone a fundamental transformation. Electric drives and high-voltage components have become central to these systems.

To support development and system integration, customers require advanced test systems capable of evaluating and optimizing both the mechanical and high-voltage electrical subsystems. Our state-of-the-art propulsion test systems are designed to validate a wide range of configurations, including different types 2WD and 4WD systems, speeds, couple, power classes, as well as high-voltage and current requirements specific to electrified systems.

Which also incorporates steering capabilities, enabling comprehensive vehicle-in-the-loop (VIL) testing. This approach creates a highly realistic testing environment essential for validating the functionality of advanced driver assistance systems (ADAS) and automated driving (AD) technologies in real-world vehicle applications.

Powertrain/Hub-coupled powertrain

Mobile (Portable) Dynamometers of Powertrain/Hub-coupled powertrain Test Bench

Mobilel/Portable axle-mounted dynamometers have become essential tools in the automotive industry for assessing powertrain performance, as they provide the flexibility and precision required in modern vehicle testing. These dynamometers enable engineers to measure power and couple in various locations, whether in workshops or within environmental chambers, providing valuable data throughout different stages of vehicle development. This adaptability ensures that manufacturers can optimize performance and verify that their vehicles meet the necessary regulatory standards.

When used in environmental chambers, portable axle-mounted dynamometers greatly enhance the ability to test vehicle performance under controlled conditions. Environmental chambers can simulate a wide range of climatic scenarios, including extreme temperatures (from -45°C to 65°C) and varying levels of humidity, all of which can significantly impact a powertrain’s efficacité and emissions. By integrating dynamometers into these chambers, manufacturers and researchers can conduct performance tests that offer valuable insights into how different environmental factors influence vehicle operation. This controlled testing is crucial for ensuring vehicles can meet emissions and performance standards in diverse and challenging conditions, ultimately helping to ensure their reliability and compliance across various markets.

1.Test Bench Architecture of Powertrain/Hub-coupled powertrain Test Bench

Powertrain/Hub-coupled powertrain Test Bench is composed of several key components, each designed to ensure accurate and efficient testing of vehicle powertrains. These components include:

  1. Mobile Low-Inertia Electric Dynamometer: The dynamometer provides precise speed and torque control, simulating real-world road load conditions. It is capable of rapid response to dynamic changes, making it ideal for simulating varying road conditions. Load simulation methods include:

    • Constant torque control

    • Calculated road spectrum simulation

    • Actual road spectrum import

    • User-defined load spectrum

  2. Dynamometer Driver: This component controls the dynamometer’s operation, allowing it to simulate different load scenarios and accurately replicate road conditions.

  3. Battery Simulator: Used to simulate the electric vehicle’s battery, the simulator can replace the actual battery and provide accurate power outputs for testing. It supports the evaluation of energy consumption and efficiency in the drivetrain.

  4. Electrical Control Cabinet: This cabinet houses the control systems for managing the dynamometer, battery simulator, and other electrical components. It plays a crucial role in regulating the overall system operation.

  5. Measurement Sensors: These sensors monitor various parameters during testing, such as temperature, pressure, couple, vitesse, and vibrations. They provide real-time data for analyzing the performance and efficiency of the vehicle’s powertrain.

  6. Vehicle Windward Cooling System: The cooling system ensures that the vehicle’s powertrain operates within optimal temperature ranges during testing, helping to prevent overheating during prolonged tests.

  7. Traffic Real-Life Simulation System: This system integrates with the dynamometer to simulate real-world traffic and road conditions. It mimics driver actions and varying road conditions, including different terrain and vehicle speeds, for a more realistic and comprehensive test environment.

  8. Main Control Computer: The central hub for system operation, this computer manages all the test processes, coordinates data acquisition, and allows for the adjustment of test parameters. It also analyzes the results and generates performance reports.

  9. Energy Flow Analysis (Power Analyzer): The power analyzer measures the current, voltage, and power consumption of each energy unit in the tested vehicle. It provides insights into the energy flow across different operational modes and creates an energy spectrum for the entire vehicle. This helps in evaluating the overall efficiency of the powertrain.

The system also allows for flexible transformation into a powertrain système de test. By connecting the battery simulatorto the powertrain drive, the system can test the powertrain’s performance under various conditions, simulating energy consumption and power distribution throughout the drivetrain components.

This architecture enables the thorough testing of vehicle powertrains, ensuring that all components work efficiently under different real-world conditions.

powertrain

The shaft coupling dynamometer adopts a flexible design. Each dynamometer adopts a movable mode. The dynamometer and the vehicle hub adopt a quick connection structure, so that the user can quickly and quickly complete the connection between the vehicle and the dynamometer. The dynamometer tray bracket is supported by universal wheels, which can be moved conveniently, and at the same time, it can also simulate the actual steering function.

The flange shaft connected to the wheel hub of the vehicle adopts a hollow structure to minimize the moment of inertia of the shaft system and improve the dynamic response capability of the dynamometer system. A transitional connection flange is designed between the flange and the wheel hub of the vehicle, and the flange also adopts a weight reduction design to reduce the moment of inertia.

2. Shaft coupling dynamometer function

The axle-coupled dynamometer is a flexible test system with a very high degree of freedom. Users can combine tests at will, and can test four-wheel drive and two-wheel drive vehicles, or separate electric drive powertrain tests. The shaft coupling dynamometer adopts a motor with extremely low inertia and uses real-time Ethernet communication control. It has a very high dynamic response speed and can complete the dynamic alternating working condition test of the load. The shaft coupling dynamometer system has the following functions:
1. Vehicle durability test
2. Vehicle energy flow test
3. Vehicle energy consumption test
4. Vehicle acceleration test
5. Vehicle road simulation test
6. Vehicle braking performance test
7. Test of universal characteristics of the whole vehicle
8. Driver in the loop test
9. Vehicle fault detection
10. Development and calibration of vehicle control strategy
11. Vehicle conformance test
12. Vehicle braking energy recovery test
13. Powertrain efficiency test
14. Powertrain speed and torque characteristic test
15. Powertrain temperature rise test
16. Powertrain controller control strategy development verification test
17. Powertrain braking regenerative energy feedback test
18. Powertrain external characteristic test
19. Powertrain development matching optimization test
20. Powertrain performance test and calibration test
21. Efficiency Map Test
22. Accelerated response test
23. Torque response test
24. Durability test of steady-state cyclic loading

3. Selection specifications of shaft coupling dynamometer

4. Technical description of vehicle energy flow test system

Pure electric vehicle driving range test will use Chinese working conditions GB/T 18386 \”Electric Vehicle Energy Consumption and Driving Range Test Method\” standard. It is determined that Chinese working conditions will replace European NEDC working conditions as the test conditions, and will be introduced High and low temperature test procedures.

Vehicle energy flow test:
1) Energy transfer path:
Based on the specific vehicle configuration, working conditions and working mode, the energy is generated and transferred/converted from the power source to the wheel end.
2) Energy transfer efficiency/loss:

In the energy transmission path, there are lossy systems and components, and the corresponding energy consumption form. The quantified energy consumption distribution for energy consumption systems and components.

Data from EPA:

The key points of the vehicle energy flow test are the accuracy of the measurement and the synchronization of the measurement of different energy-consuming components, as well as the authenticity of the vehicle condition simulation.
In order to improve the accuracy of electric energy measurement, it is necessary to configure a high-precision power analyzer and transformer, and use a power analyzer with a high-precision synchronous clock function to synchronously collect and measure the signals of each sensor.

Vehicle energy flow test:

powertrain

5. Software System

The software system is mainly divided into the following parts:

★Test management software: Before the test, test basic parameters and related control parameter settings, generate test information files, and be called by the test main control software.

Through the interaction with the real-time control computer during the test, the test process is automatically managed and the specified real-time information is processed.
After the test is completed, test reports, test record retrieval, data post-processing, etc.. are generated.
★Real-time control software of test bench: Through the acquisition of closed-loop control sensor information, and through interaction with the test management computer to obtain the upper-level solved control parameters, and do the necessary lower-level calculations, real-time closed-loop control of the speed and torque of the driving and loading motors and other Real-time control of auxiliary facilities.
★Human-computer interaction processing software: A unified human-computer interaction interface that integrates the main information on the same machine; real-time display of test progress, main test data, the status of the test piece and the test bench and other information.
★Test data acquisition and post-processing software: The system provides various mathematical operations of data, including addition, subtraction, multiplication, division, integration, differentiation, maximum value, minimum value, peak value, RMS, average, sum, etc..
All software systems used adopt modular design ideas, with good flexibility and scalability. The main functional modules of the software are: main program framework module, system control module, data acquisition module, data recording module, data analysis module, data display module, communication module, data playback module, print processing module, sensor calibration module, function setting module, Help document module and data post-processing analysis module, etc..
5.1 Main test interface

After the vehicle has undergone the loss calibration and coasting test, the formal test is carried out. At this time, the simulated load of the dynamometer is similar to the road load of the vehicle.

5.2 Calibration of friction loss
Before the user starts to use the device for testing, the device needs an effective friction calibration (the device will only be used if it exceeds a certain speed corresponding to the friction calibration). The user can check the calibration status through the dial control page that displays the calibration status.
Users can perform friction calibration regardless of whether the vehicle is equipped or not, but the system cannot distinguish between equipment friction loss and vehicle loss at this time. Therefore, the user needs to make a new loss calibration for each new car. It is recommended to do friction calibration where the vehicle is not equipped.

At the same time, the user needs to consider that the friction loss will change with the change of the ambient temperature. Therefore, it is necessary to warm up the device before friction calibration or test and maintain its temperature until the end of the test.

5.3 Vehicle loss calibration

When the vehicle loss calibration is completed, the page will automatically update and display the maximum calibration speed. The calibration of friction loss can be analogized to the calibration of vehicle loss. The maximum calibration speed displayed is the lower of the friction calibration speed and the vehicle loss calibration speed.

5.4 Basic inertia calibration

The basic inertia calibration is used to calibrate the basic inertia of the test bench, including: the total moment of inertia of each transmission system such as the drum, drive shaft, and motor. The basic inertia calibration is a necessary condition for the correct operation of the test bench.

5.5 Glide test

In the taxiing process, the system first accelerates the device to above the maximum speed required for taxiing, and then enters the road simulation mode to simulate the road environment until the device is below the minimum speed required for taxiing. When passing the designated speed point, the time at this time Will be recorded. The system can accurately calculate the road simulation by calculating the time and the average deceleration force for the specified taxi distance. Users can find this information on the taxi results page.
5.6 Road load simulation
The system can provide various series of dynamometer electromechanical inertia simulation, and simulate the road load according to the equation:
RL = F0 + F1VX+ F2Vn+ I dv/dt + mg * (Grad/100)
among them:

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