E-Drive Testing

At our testing facility, we examine the functional aspects of the powertrain, carry out conventional endurance tests, and measure the efficiency of the various systems involved. We perform the tests using a wide range of technologies (e.g. PMSM, ASM, or EESM).

Our modular test rig concept enables us not only to examine the operation of the system under test, but also to integrate further features in order to represent realistic scenarios: coolant and oil conditioning in various performance classes, temperature overlay during operation, or even high-precision measuring technology to determine power and torque characteristics. Tests can be performed at up to 30,000 rpm, 700 kW of mechanical output, and more than 800 kW of electric power.

We support you right from the start in all phases of the product life cycle. By using universal converters, we can put electric motors into operation at an early stage in the development process and carry out initial tests. As the project proceeds, we also examine both the product design and the final product properties. During ongoing series production, we carry out random checks to monitor the quality of the components.
 

When developing electric axles, it is essential to design and build the components and subsystems in accordance with their specific requirements. The increasing integration of the inverter, electric motor(s), and transmission in a single housing means that these need to be validated together on high-performance axle drive test benches in order to optimize the overall system. At Bertrandt, both single-motor and dual-motor axles are tested, but we can also test so-called 3E systems with an additional high-speed electric machine. For all possible variants, our comprehensive testing technology ensures efficient and reliable testing for the targeted examination of the product’s properties.

Due to their modular concept, our electric axle test rigs also enable additional features for subcomponents to be integrated in order to create realistic test scenarios. This ensures that your project-specific requirements regarding environmental conditions, measured variables, or the simulation of auxiliary units can be covered with a high level of efficiency.

An electric all-wheel drive system allows torque to be transferred extremely precisely, as each wheel can be individually controlled. We can create an all-wheel drive vehicle in the laboratory by linking two separate axle test benches via intelligent automation of our test facilities. This enables us to transfer our testing activities efficiently from the complete vehicle into the laboratory. Power outputs of up to 480 kW and torques of up to 4,800 Nm at a maximum speed of 3,000 rpm can be implemented for each wheel.

In order to guarantee the durability of the motor during subsequent operation, the validation of the dynamic strength of the rotor is one of the most important aspects in the development process. The strength values determined by simulation can be checked at an early stage in a subcomponent test. In addition to testing the durability of rotors during speed change tests, we also carry out tests in the limit range (burst tests).

By using a special testing system, we can already test the power electronics and inverters at an early development phase and independently of the existing electric motor. The testing system creates an optimized test environment and a very efficient verification process. That means that less time is required compared to testing the unit under test (UUT).

We provide inverter tests that are tailored to your specific requirements to validate one of the central components of the electric drive system. A test environment developed by Bertrandt and which is specifically adapted to the inverter, as well as a range of other special solutions for testing inverters, ensure the highest level of efficiency and at the same time maximize the informative value of each test. Here, too, you benefit from a significantly reduced amount of time required compared to the testing of complete units. In addition, tests can be carried out even before the electric machine is available, thus reducing the amount of effort required for complete testing.

Our services cover the following areas:

• Systems with a nominal voltage of 48V, 400V, or 800V
• Functional testing
• Electrical tests
• Environmental and lifetime testing
• The load is usually simulated by using specific inductances or alternatively by substitute motors

By using our own test bench solution for power electronics assemblies, we achieve maximum efficiency coupled with a high level of adaptability to the respective test.

Environmental influences play a key role in the performance and service life of electric drive systems. Whether it is moisture, extreme weather, or pollution: the variety and intensity of the environmental influences depend on the usage scenarios of the drive system that is installed. Bertrandt offers you a very powerful and diverse infrastructure as well as many years of expertise for all kinds of environmental simulation tests.

This includes all standard test methods, such as thermal, climatic, mechanical, and chemical tests, as well as a variety of special solutions, such as the combination of various environmental influences in a common test setup, thus reducing testing effort, minimizing test times, and increasing the overall efficiency of the test to maximize the informative value of the results. All tests have quality assurance according to DIN ISO 9001 and, in some cases, according to DIN ISO 17025. An additional standard for all applications is work carried out according to TISAX requirements.

Environmental simulation

A vitally important part of every vehicle is an on-board electrical system that functions properly under all operating conditions. It not only ensures the proper functioning of the components in the system, but it also contributes to the overall performance and safety of the vehicle. For that reason, each and every component that is integrated into the vehicle’s electrical system must function reliably and efficiently in the required operating states.

In order to validate both individual components and the entire on-board electrical system, we carry out tests on the powertrain in both the low-voltage and the high-voltage range (LV: 12V, 24V, 48V / HV: 400V, 800V). We test according to all common standards, such as LV124, LV148, and VDA 320. The realistic load and operating conditions that are necessary for reliable results can be recreated on our modular engine and axle test stands.

Are you looking for a reliable development partner for your electric mobility drive concept? Our comprehensive development support goes far beyond actually performing your test. We can also support you right from the start, for example in choosing the right test strategy, in test planning, or in creating the necessary test specifications. We use a wide range of automation and analysis tools to make the test results available quickly, consistently, and with a high quality.

Our own laboratory provides you with support in the final diagnosis of your components, especially in the area of ​​power electronics and the associated components.

Bertrandt is your reliable partner for testing electric drive systems and drive components for vehicles. With innovative technologies for testing, a wide range of test resources, and an expert network with a comprehensive understanding of the product, Bertrandt has been a reliable partner for many OEMs for more than 50 years. With our testing and validation services, we support our customers in guaranteeing the maximum service life of their products and help to ensure that their products can meet all the specific requirements of the industry and their target markets. Our range of services extends far beyond the validation of components and systems. We support you by providing a source of inspiration and apply our expertise to optimize your product together with you.