NEW ENERGY TESTING SOLUTIONS

AUTHOR: Mr. Redzo Sakanovic
Application & Integration Leader

The GETEC E-Mobility test benches have been developed in cooperation with GTSystem with focus to the new challenges introduced by the requirements for electrified or electric drivetrains. In particular, the trend towards higher speeds for electric drives was considered in the design. We offer our customers a highly modern test environment that is constantly being further developed.

With GETEC as development partner, right away from project start support by engineering team is possible.

Fig. 4 | 1-Dyno bench (Simulating the drive motor)

 

The test environment is designed in such a way that it is possible to react extremely flexibly to customer requirements. Drivetrains from (mild) hybrid applications (HEV), plug-in hybrids (PHEV) to battery-electric vehicle drives (BEV) can be tested. The modern and „state of the art“ equipped e-mobility test environment includes highly dynamic drive machines that enable a range of speeds of up to 22,000 rpm and a torque of up to 700 Nm (refer to Figure 4).

 

To test the entire drive unit, output machines with a power range of 3,000 rpm and a torque of 3,500 Nm are available. In Figure 5 a 2-Dyno bench is introduced. The output is simulated by the output dynos left and right.

 

If there is no input motor or if only the gearbox for an electric drive is to be tested, a 3-Dyno configuration is set up as shown in Figure 6. Here the drive of the gearbox as well as the output are simulated with test bench machines. Beside this layout, also a longitudinal layout is possible to be realized.

Figure 5 | 2-Dyno bench (Simulating the output)

Another important component is the simulation of different temperature environments. The cold and hot tests are also part of the LV123 test specification. The temperature simulation is implemented using a climatic chamber (-70 °C to 180 °C) and additional coolant conditioning (-30 °C to 130 °C). Due to this large configuration bandwidth, various test execution variants are available:

  • Function tests
  • System tests
  • Security checks
  • Measurement services

The sensors used at GETEC are DAkkS certified to comply with the deviation tolerances required in the specification for speeds, torque, current, voltage, pressure, and temperature.

To achieve the jointly set targets in the specifications, open communication with our customers is very important. Because of this, the customer is informed ad hoc about the current test progress at any time. This allows the engineers to intervene in the development process in shortest time and take countermeasures. To be able to optimally involve the development engineers of the customer, various online support methods are available to be able to do program adjustments / adjustments in test sequences in real time during commissioning.

Fig. 6 | 3-Dyno bench (Simulating input and output)

For the first phase of developing the electric motor (standalone), we can offer our customers an engineering service and control the electric motor via a development inverter. With GETEC as development partner, right away from project start support by engineering team is possible.

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