Engineering Service and Testing
Electrification Engineering
We’ve taken strategic steps to augment our core capabilities to support all our customers’ drivetrain and propulsion needs, regardless of the power source. Whether our customers are looking to build a vehicle powered by a traditional or emerging energy source, we leverage our broad and flexible offering to deliver customized and integrated solutions for any application. Our seasoned, highly qualified team of electrical and mechanical engineers and software programmers work in unison to provide our customers top quality development talent, supporting our customers across the globe!
- CAD packaging of components and systems into chassis structures
- 3D design of all components, peripherals and systems
- Preparation of product and manufacturing information
- Prototype development, build and assembly
- Electrical systems (high/low voltage); circuit diagram design; cable harness design
- Conception of electrical safety features with focus on high voltage components
- Preparation of product and manufacturing information; build and assembly of wiring harness, measurement system and high voltage battery prototypes
- Organizational integration of VEFK (Responsible Electrically Qualified Person) in accordance with norm DIN VDE 1000 10; AuS (Live Line Working) certification
- Design of functional simulation models in MATLAB /Simulink
- Conception and modeling of driving strategies
- Model based design and conventional programming in C
- Calibration of software parameters to obtain desired function on vehicle management units
- Design, programming and calibration of closed loop operational strategies for complex vehicle and propulsion systems
- Creep control; speed limiter; deceleration control; traction control; hill hold; torque vectoring; transmission
- Model, software, hardware, and driver in the loop
- Validation and verification of all systems regarding function and safety
- Calibration via simulators, test benches, dynamometers, in-lab and on test vehicles
- Commissioning assistance and field support
- Technical monitoring through our qualified staff
- Remote support
- Performance tweaking and troubleshooting
Electric Vehicle Testing
Today’s market for electric traction concepts and performant drive systems is growing, the pressure for speed in the associated development cycles is increasing all while demands on quality and safety continue to rise. For those seeking not simply to meet this challenge on a technological and procedural level, but to be capable of proactively generating competitive advantages, we see the intelligent integration of test bench measurement technology within the development process to be a powerful, highly sensitive adjustment screw enabling the achievement of future oriented engineering in one of the most promising and important traction segments of our time.
The electric powertrain components electric motors, gearboxes, inverters and traction batteries are subject to the highest quality standards and must be able to fulfill a wide variety of performance and safety conditions.
Powertrain-in-the-Loop (PIL)
Our Powertrain-in-the-Loop (PIL) dynamometer allows us to realistically simulate all load conditions, and thereby define all parameters needed for the characterization and validation of system components. An integrated e axle unit with separate side mounted load and brake motors makes it possible to subject complete drive units consisting of an electric motor, inverter, gearbox, control unit and traction battery to true to life driving simulations with authentic road load. In our battery test bench, we can also test and validate everything from individual modules to complex traction batteries for their load and continuous load characteristics as well as their charging and discharging cycles.
Powertrain-in-the-Loop Fields of Application
- Testing and evaluation of individual components (electric motors, gearboxes, inverters, batteries)
- System testing of components in flexible combinations
- Continuous load testing of complete electric drive systems
- Performance data verification of electric drive systems
- Validation and characterization of high-energy storage-devices (traction batteries)
- Testing and evaluation of brake energy recovery
Performance Meets Flexibility
Our Powertrain-in-the-Loop dynamometer in numbers.
PIL Technical Data
- Select voltage range (Battery model implementable): 20-1000 Vdc
- Traction (continuous): 250 kW
- Recuperation (2 brake motors): 330 kW
- Maximum braking torque per wheel: 3500 nM
- Maximum rotations per wheel: 3375 rpm
- Battery charging and discharging (continuous): 250 kW
- Battery maximum discharge: 330 kW
- Single wheel control for differential or torque vectoring analysis
- Programmable battery models and CAN interfaces
- Powerful dSpace Scalexio HIL simulator
Variable Conditioning System for Cooling Circuits of Battery, Inverters, and Motor
- Maximum coolant temperature: 140 C
- Maximum volume flows: 30 l/min
- Heating capacity: 2x4 kW
- Cooling capacity: 2x15 kW