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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 (电磁兼容). 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.

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

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 RPM400 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 robustreliable products.

Electric axle test bench for NVH/EMC

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 (电磁兼容) of e-drive systems and assess both their 排放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 排放免疫 of your e-axle components, guaranteeing the reliabilitycompliance 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, 和 效率, preparing them for integration into next-generation mobility solutions.

测功机


我们提供几种类型的测功机,例如:
GZC系列滞后测力计,
GZF系列磁粉测功机,
GZW系列涡流测功机, GZDL系列电力计.
可测量的参数:
DC (或者 单相 交流) 发动机:
输入功率P1, 电压u, 当前i (功率因数, 频率) 输出功率P2, 扭矩t, 速度N效率.
-阶段 交流 发动机:
输入功率P1, 电压u, 当前i (功率因数, 频率) 输出功率P2, 扭矩t, 速度N效率.
发动机 司机:
驱动器输入功率P1, 电压u, 当前i (功率因数, 频率) 驱动器电动机P2, 电压U1-U2-U3, 当前的I1-I2-I3, 功率因数, 频率电动机输出功率P3, 扭矩t, 速度n驱动效率, 运动效率, 整体机器效率.

电机测试系统


用手动, 定点, 和自动测试方法, 可以根据设置自动加载负载, 电动机的特征曲线从无负载到阻塞 (或设置值) 可以扫描;测试结果: 电机测试数据以报告或曲线的形式显示或打印, 可以保存和查看; 显示曲线时, 可以修改曲线坐标参数以及横坐标和纵坐标的选择;
可衡量 参数; 驱动器输入电压, 当前的, 电动驱动器输出电压, 当前的, 力量, 功率因数, 频率电动输出扭矩, 速度, 动力驱动效率, 运动效率, 总运动效率.

电驱动系统 EMC/EMI 测功机系统


随着电驱动系统的快速发展, 尤其是新能源汽车, 电磁兼容问题越来越受到关注. 新能源汽车电驱动系统具有高电压的特点, 高电流, 结构复杂, 以及多样化的耦合路径, 并且是干扰的主要来源。在模拟的实际负载条件下,电动驱动EMC/EMI测试系统由态室组成, 测功机系统, 电池模拟器, 功率放大器及其屏蔽室, 控制室及其屏蔽室, 冷却系统, 和屏蔽轴系统. 根据CISPR25的要求, GB/T18655, GB/T36282, GB/T18387等标准, 可以满足传导发射, 辐射发射和辐射抗扰度, 电池组的大电流注入等测试, 电机, 控制器, 动力总成, ETC. .

车轴联轴器测功机系统


车轴耦合测试计测试系统由移动低渗透测功机组成, 测功机驱动器, 电池模拟器, 电控制柜, 测量传感器, 车道冷却系统, 交通现实生活中的模拟系统, 主控制计算机, 电气控制柜和其他组件。测功机可以执行速度和扭矩控制以模拟道路负载. 负载模拟方法包括: 恒定扭矩控制, 计算出的道路频谱模拟, 实际的道路频谱进口, 和用户定义的负载谱. 电源分析仪测量电流, 测试车辆的每个能耗单元的电压和功率, 在不同的操作条件下分析车辆的能量流, 并绘制整个车辆的能源. 测功机采用低惯性测功机, 具有极高的动态特征,可以模拟快速变化的工作条件并模拟不同的道路模型. 通过集成到交通场景模拟系统中, 可以真正复制在不同道路条件下的实际车辆行动, including the driver's operating comfort. 该系统也可以转换为动力总成测试系统, 电池模拟器可以连接到动力总成驱动器以测试动力总成.

车辆EMC/EMI测功机系统


车辆EMC/EMI测试系统通常由室内室或混响室组成, 测量 乐器, 以及模拟车辆道路负载的集线器测功机系统. 旋转集线器测功机 模拟车辆负载的系统可以设计为两轮驱动, 四轮驱动或更多轴驱动器 测功机根据车辆的驱动轴数量. 测功机系统也可以采用 结构类型嵌入转盘, 或移动类型.

传播 (减速器) 测试系统


高速还原测试台由低惯性负载模拟测功机组成, 高速紧凑驱动电机, 变频器, 环境室, 冷却系统, 高精度传感器, 振动监控和预警系统, 机械系统, 测功机的实时控制系统, 以及主要的控制系统和其他部分. 用于电动驱动器测试台, 不需要高速驱动器, 仅惯性负载模拟电动机. 实时动态控制系统可以通过实时控制器实现速度和扭矩控制,并模拟实际负载. 主控制系统可以与环境室通信, 电力分析仪, 冷却系统, 尤特, ETC。, 并实现控制. 数据采集​​系统从扭矩传感器收集信号, 振动传感器, 温度传感器, 压力传感器, 和其他传感器, 并以高速传输到主控制系统. 传感器数据可以显示, 保存并处理在软件接口中.

航空定制高速传输测试系统


我们为航空高速传输系统提供定制的测试系统, 例如高速发电机, 高速变速箱, ETC. 各种类型的置, 测功机系统和电气负荷可以根据实际需求设计.

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