// 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
Auto­ma­ti­on
  • 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
  • CAN rest­bus simu­la­ti­on for batte­ry control unit

“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 

Haupt­stand­ort Land­au
APL Auto­mo­bil-Prüf­tech­nik
Land­au GmbH
Am Hölzel 11
76829 Land­au

 

// Wolfs­burg
APL Auto­mo­bil-Prüf­tech­nik
Land­au GmbH
Gustav-Hertz-Stra­ße 10
38448 Wolfs­burg

 

// Bietig­heim-Bissin­gen
APL Auto­mo­bil-Prüf­tech­nik
Land­au GmbH
Robert-Bosch-Stra­ße 12
74321 Bietig­heim-Bissin­gen

// APL Group

APL Auto­mo­bil-Prüf­tech­nik Land­au GmbH

AIP GmbH & Co. KG

APS-tech­no­lo­gy GmbH

IAVF Antriebs­tech­nik GmbH

IAVF-Volke Prüf­zen­trum für Verbren­nungs­mo­to­ren GmbH

MOT GmbH