// Elec­tri­fied Powertrains

Alter­na­ti­ve Power­trains — Meeting Current and Future Challenges

We star­ted the first tests of alter­na­ti­ve power­trains as early as 2003, initi­al­ly with elec­tric motors inclu­ding power elec­tro­nics, and then with high-volta­ge batte­ries. In the cour­se of deve­lo­p­ment in recent years, our test­ing port­fo­lio has expan­ded enorm­ously: from the comple­te HV network (power supp­ly system via char­ging stati­on), to onboard char­gers, HV batte­ries, inver­ters, elec­tric motors, trans­mis­si­ons, diffe­ren­ti­als, shafts, and oil supp­ly investigations.
Control room for clima­te cham­bers for batte­ries and ‘back-to-back’ tests
Clima­te chamber
High frequen­cy measu­re­ments on an osciliscope
In order to stay ahead of rapid deve­lo­p­ment curves, we are constant­ly opti­mi­sing our tech­ni­cal test­ing equip­ment and measu­ring tech­no­lo­gies. We invest a lot of money in the inter­nal and exter­nal trai­ning of our employees. Only with high­ly quali­fied engi­neers and employees can we reali­se new, extre­me­ly complex test condi­ti­ons. Our goal is to be able to repro­du­ce the comple­te spec­trum of alter­na­ti­ve power­train concepts at any time – from simp­le compon­ents to high­ly complex HV compo­si­te test benches, inclu­ding char­ging infrastructure.
Project Support
  • One cont­act person for the enti­re project
  • Setup design and support
  • Commis­sio­ning
  • Test proce­du­re programming and testing
  • Test proce­du­re opti­mi­sa­ti­on and control
  • Measu­re­ment data evalua­ti­on, analy­sis and assessment
  • Trou­ble­shoo­ting and problem solving
  • Coor­di­na­ti­on of depart­ments and processes
  • Project time­line and budget monitoring
  • Daily status report
  • Inter­face manage­ment — exter­nal and internal
  • Test result docu­men­ta­ti­on and presentation
Mecha­ni­cal Construction
  • Indi­vi­du­al solu­ti­ons for every type of cons­truc­tion and connection
  • Wheel, cardans­haft, VKM simu­la­ti­on, high speed dynamometers
  • Up to 5 dynamometers
  • Vibra­ti­on-opti­mi­sed test bench construction
  • Back-to-back cons­truc­tion with and without clima­te chamber/hood
  • 0° shaft alignment
  • Rota­ti­on speeds up to 24,000rpm
  • Torques up to at least 2,500Nm
Elec­tri­cal Construction
  • Produc­tion of wiring looms and either direct connec­tion or via cont­ac­tor boxes
  • Tests with your or an APL converter
  • Curr­ents (DC) of 600A /1200A (with paral­lel connec­tion) with high dyna­mics (0 è 100A in 0.3 ms)
  • Elec­tri­cal power (DC) of 150kW / 300kW (with paral­lel connection)
  • Maxi­mum volta­ges (DC) of 1,000V
  • Dyna­mic DC supp­ly (source/sink)
  • Tempe­ra­tu­re cham­ber with safe­ty technology
Measu­re­ment Technology
  • Elec­tri­cal power measu­re­ment; speci­fic testers for elec­tri­cal machi­nes and complex test benches; high-precis­i­on measu­re­ment technology
  • HBM T12 torque measu­re­ment with various measu­re­ment ranges
  • Power measu­ring devices
  • Storage oscil­lo­sco­pes
  • Vibra­ti­on measu­re­ment tech­no­lo­gies (e.g. Reil­ho­fer or Müller BBM)
  • Snif­fer measu­ring device
  • Insu­la­ti­on and winding resis­tance measurements
  • Motor test­ing equip­ment (Schleich GLP1‑e HV)
  • HV-safe evalua­ti­on units
  • Rotor measu­re­ment by means of 3D measu­ring machine
  • Posi­tio­ning of measu­re­ment tech­no­lo­gy close to test specimen
  • High repro­du­ci­bi­li­ty
  • Conti­nuous recor­ding of measu­re­ment values up to 1kHz
  • Post­mor­tem measu­re­ment data
Addi­tio­nal Aggregates
  • Addi­tio­nal measu­ring tech­no­lo­gy and condi­tio­ning can be used project-dependent­ly; media condi­tio­ning is adapt­ed to the requirements
  • Inde­pen­dent condi­tio­ning LE / EM (-40°C — + 130°C)
  • Oil condi­tio­ning
  • Circu­la­ting air condi­tio­ning (-40°C — + 180°C) by means of clima­te cham­ber or clima­te hood
  • Control engi­neers for prompt, project-speci­fic adjustments
  • Flexi­ble control
  • Auto­ma­ted condi­tio­ning and mapping measu­re­ments (with refe­rence point monitoring)
  • Rest­bus simulation
  • Battery simu­la­ti­on:
    • With an elec­tri­cal simu­la­ti­on model, the char­ge and dischar­ge of Li-Ion batte­ries can be mode­led. This way, within the test setup (e.g. hybrid drive), the Li-ion battery is comple­te­ly repla­ced by a controll­able DC volta­ge supply.
  • CAN rest­bus simu­la­ti­on for battery control unit
  • Driving resis­tance
  • Auto­ma­ted driving
  • Time-opti­mi­sed testing

“In our sector there are never two projects which are exact­ly the same. This ensu­res varia­bi­li­ty and keeps things exciting.”


Lisa Z., Project Engi­neer

Dura­bi­li­ty Testing
Various loads are tested here across the enti­re life­time, vali­da­ti­ons of elec­tric power­trains are carri­ed out (in accordance with rele­vant stan­dards and custo­mer speci­fi­ca­ti­ons) and bearing/rotor tests are implemented.

High­ly dyna­mic situa­tions can be simu­la­ted using DC power suppli­es and test rig machi­nes. In addi­ti­on, auto­ma­ted running of charac­te­ristic diagrams and inter­me­dia­te measu­re­ments are perfor­med. The basic condi­ti­ons — for exam­p­le, influence of ambi­ent tempe­ra­tu­re (-40°C — 150°C) or humi­di­ty — can be easi­ly adjus­ted. It’s also possi­ble to inte­gra­te special condi­tio­ning, aggre­ga­tes, or special measu­re­ment tech­no­lo­gy at any time.

Func­tion­al Investigations
For func­tion­al test­ing, many diffe­rent tests are auto­ma­ted or perfor­med manu­al­ly. The goal is to deter­mi­ne and test the full perfor­mance spec­trum, tempe­ra­tu­re deve­lo­p­ment, beha­viour in case of fail­ure, and basic func­tions of a prototype.

Usual­ly, these tests are very time-consum­ing and requi­re a lot of funda­men­tal know­ledge, as they’re neither tried and tested speci­mens nor stan­dard proce­du­res. The tests include mapping measu­re­ment, maxi­mum charac­te­ristic curves (inclu­ding S1 opera­ti­on), short-circuit and no-load charac­te­ristic curves, back-EMF measu­re­ment, tran­si­ent load beha­viour, ther­mal inves­ti­ga­ti­ons and others. Often, these tests are also used to cali­bra­te a test item or to check the application.

Envi­ron­ment Simulation
During the deve­lo­p­ment of a new compo­nent, it’s neces­sa­ry to check safe­ty and dura­bi­li­ty, detect weak­ne­s­ses and deve­lop appro­pria­te measu­res. For exam­p­le, the influence of great heat, cold or moist air is tested on the test speci­men (water­pro­of­ness, pene­tra­ti­on of objects/dust and vibrations).
Type Appr­oval, COP and EOL
At the end of the deve­lo­p­ment process, we are able to reali­se type appr­oval with the most diver­se requi­re­ments for speeds and power.
Confor­mi­ty of Produc­tion (COP) is carri­ed out during the produc­tion cycle in order to ensu­re key perfor­mance of the elec­tric machi­ne as deter­mi­ned during type approval.
End-of-line (EOL) tests are prima­ri­ly used for quali­ty assu­rance and are carri­ed out at the end of a product manu­fac­tu­ring process. We can offer these tests during the deve­lo­p­ment process.
Back-to-Back / Back-to-Front
Test proce­du­res, in which two test items are mecha­ni­cal­ly connec­ted direct­ly or via gears, can be opera­ted in clima­tic cham­bers by means of a clima­tic hood, or without condi­tio­ning of the ambi­ent air.
Simu­la­ti­on Vehic­le / Road / Driver
The display of driving profiles — for exam­p­le, legal or custo­mer-rele­vant cycles — is important for test­ing e‑drive components.

The real-world effi­ci­en­ci­es, the total ener­gy demand, the ther­mal beha­viour and the dura­bi­li­ty test play a major role here.

Inves­ti­ga­ting Coolants and Lubri­cants (e‑fluids)
Coolant and lubri­cant func­tion­a­li­ty can be tested on exis­ting elec­tri­cal axles and elec­tri­cal dyna­mo­me­ters. Depen­ding on requi­re­ments, we can provi­de pure elec­tric motors, hybrid drives, trans­mis­si­ons or even enti­re vehic­les for test­ing on one to four-dyno test benches or chas­sis dynamometers.
2WD / 4WD
Our test bench concept is so flexi­bly desi­gned that
  • comple­te vehic­le drive­trains (4‑machine super­s­truc­tures incl. battery or battery simu­la­ti­on), two-machi­ne super­s­truc­tures (e.g. for axle tests) or
  • test bench setups can be tested with only one dyna­mo­me­ter for pure elec­tric motors. As a rule, we can reali­se any and all custo­mer requirements.
Rela­ted Topics:

Deve­lo­p­ment of Elec­tric Powertrains

Chemi­cal and Physi­cal Laboratory

// Loca­ti­ons 

Head­quar­ters Land­au
APL Auto­mo­bil-Prüf­tech­nik
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Land­au GmbH
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// APL Group

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AIP GmbH & Co. KG

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IAVF-Volke Prüf­zen­trum für Verbren­nungs­mo­to­ren GmbH


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