Powertrain systems primarily relied on transmission concepts before, such as manual, automatic, and dual-clutch transmissions for 2WD and 4WD vehicles. 然而, 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, 扭矩, 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.
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 力量 和 扭矩 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 效率 和 排放. 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 排放 和 performance standards in diverse and challenging conditions, ultimately helping to ensure their reliability and compliance across various markets.
Powertrain/Hub-coupled powertrain Test Bench is composed of several key components, each designed to ensure accurate and efficient testing of vehicle 动力总成. These components include:
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. 负载模拟方法包括:
Constant torque control
Calculated road spectrum simulation
Actual road spectrum import
User-defined load spectrum
Dynamometer Driver: This component controls the dynamometer’s operation, allowing it to simulate different load scenarios and accurately replicate road conditions.
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.
Electrical Control Cabinet: This cabinet houses the control systems for managing the dynamometer, 电池模拟器, and other electrical components. It plays a crucial role in regulating the overall system operation.
Measurement Sensors: These sensors monitor various parameters during testing, such as temperature, pressure, 扭矩, 速度, and vibrations. They provide real-time data for analyzing the performance and efficiency of the vehicle’s powertrain.
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.
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.
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.
Energy Flow Analysis (Power Analyzer): 电源分析仪测量电流, 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 测试系统. By connecting the 电池模拟器to 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.
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, 同时, it can also simulate the actual steering function.
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.
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:
Vehicle energy flow test:
★Test management software: 测试之前, test basic parameters and related control parameter settings, generate test information files, and be called by the test main control software.
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.
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.
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.
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
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