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E-Axle Test Bench

E-Axle Test Bench

Электрические приводы лежат в основе обоих электромобилей аккумулятора (Бевс) и электромобили с топливными элементами (FCEV), 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, Вибрация, Резкость (Н.В.) 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, шум, вибрация, and harshness (Н.В.), 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, механический, and thermal property analysis. This advanced test system enables precise performance and functional testing at speeds up to 20,000 об/мин and power levels up to 400 кВт, supported by a direct drive dynamometer, flexible multi-channel cooling conditioning, and a climatic chamber for comprehensive environmental simulation.

А 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, электрический, 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

А 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 об/мин и 400 кВт. 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 испытательная скамья 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 с 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 и reliable products.

Electric axle test bench for NVH/EMC

А electric axle test bench for NVH is designed to redefine silence, comfort, and overall производительность 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 и immunity to interference, specialized EMC test systems are essential. We offer precise EMC measurements and testing in accordance with the Циспр 25 standard, ensuring that your systems meet the most stringent industry regulations.

This solution allows for effective evaluation of both the emissions и immunity of your e-axle components, guaranteeing the reliability и 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, Вибрация, 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 производительность, reliability, и эффективность, preparing them for integration into next-generation mobility solutions.

Тестовая скамья моторной фабрики

Motor Production test: Тестовая скамья моторной фабрики

Test Overview:
This system adopts an embedded architecture and is a professional control system software developed based on the Linux platform. It combines the stability of the Linux system with the user-friendly interface of the Windows system, enabling fast and accurate testing of the comprehensive electrical performance parameters of a complete motor. With one-time installation and a one-stop approach to completing all test items, it reduces manual intervention and enhances production efficiency.

Тестовые элементы:
Voltage withstand, insulation, resistance, no-load

Motor Factory Testing System

Функциональные особенности:

    • Intelligent: The system can connect to the external internet via a network interface, enabling data interaction and resource sharing to meet the needs of next-generation IoT.

    • Modular: The test modules are completely independent, allowing for serial or parallel testing based on requirements, as well as single-station or multi-station combined testing modes.

    • High Performance: Compatible with testing items such as voltage withstand, insulation, resistance, and no-load.

    • Easy Maintenance: Supports intelligent self-diagnosis, remote fault diagnosis, and online software upgrades, with a plug-in board design for easy disassembly and replacement.

    • High Efficiency: One-time wiring completes all performance tests in a single process, with six tests for single-speed single-phase asynchronous motors completed within 5 seconds.

    • Rich Interfaces: The instrument is equipped with USB, LAN, RS232, RS485, and other interfaces, supports TCP/IP network protocols, and includes PLC simulation technology for convenient instrument control and expansion.

  • Data Management: Features test item editing, test report export, test data analysis, and the ability to enable or disable individual test items as needed.
  • Withstand Voltage OutputRange: (300-5000)VAC, Step: 10V/Step
    Setting Range / ТочностьТочность: ±(2.5% × Set Value +10V), Loss Factor: <3%
    Withstand Voltage Breakdown Current Measurement Range / ТочностьRange: (0.10-100.00)mA Accuracy: ±(2.5% × Reading + 5 digits)
    Withstand Voltage Breakdown Current Alarm Threshold RangeUpper Limit: 0.10 ~ 100.00mA Lower Limit: 0.00 ~ 5.00mA
    Insulation Resistance Output VoltageRange: (200-1000)VDC, Step: 5V/Step
    Точность±(3% × Set Value +5V)
    Insulation Resistance Measurement Range / ТочностьRange: (1*1000)MΩ Accuracy: ±(3% × Reading +5 digits), ≤200MΩ (±5% × Reading +8 digits), >200
    Winding Resistance Measurement Range / ТочностьRange: 0.1-0.2/2/20/200/2k/20kΩ, 1~100mΩ Accuracy: ±(0.3% × Reading +3 digits) (Temperature Compensation Available)
    No-load Voltage MeasurementRange: 0-600V Accuracy: ±1% of Reading + 0.05% Full Scale
    No-load Current MeasurementRange: 0-14Arms Accuracy: ±1% of Reading + 0.05% Full Scale
Тестовая скамья моторной фабрики
Тестовая скамья моторной фабрики
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