Testing facility for electric machines in the automotive sector: 

Bertrandt develops specific testing concepts and has the necessary testing facilities at its disposal for electric motors and also the entire electric or electrified powertrain. Everything from (mild) hybrid systems (HEV) and plug-in hybrids (PHEV) to purely battery-powered vehicles (BEV) is covered here. We calculate characteristic curves and efficiencies, carry out speed change tests, and offer comprehensive lifetime tests.

• Determination of efficiency: Efficiency levels greatly exceeding 90% in electric drives are very demanding on the reproducibility and measurement accuracy of the testing and measuring systems. Our testing systems are capable of measuring improvements in efficiency in the tenth of a percentage range with a high level of reproducibility and validity.
• All-wheel drive chassis dynamometers: On the chassis dynamometer we currently have in place, we are capable of validating vehicles with a nominal output of 550 kW or carrying out range measurements.
• Trend toward 800 volt systems: We test not only conventional 400 V power components, but 800 V systems too.
• Trend toward higher speeds: In electric drive systems, we detect a clear trend toward higher revolution speeds in coming years – even as high as 25,000 or 30,000 rpm. Our testing facilities for electric machines are already equipped to handle this new generation of drive systems now.
• Trend toward multiphase systems: 6-phase components, such as multiphase converters, are increasingly being used instead of the 3-phase systems used previously. That is why Bertrandt has adapted and expanded its testing and measuring systems for these new components.

Validation of power electronics 

We conduct full-scale validation programs for power electronics for notable OEMs and system suppliers. In addition to conventional environmental simulations, we also test operational stability – but the electrical and functional features of the drive systems are also important areas of testing.

• Consistency: Our job begins with the development of the testing plan and specification to ensure we achieve the required testing coverage. Our validation specialists then accompany the entire development process, right to the start of series production. And when testing needs arise or changes to testing procedures occur at short notice, we are able to respond with skilled project management and a high number of testing systems.
• Transparency: We are committed to maximum transparency when informing customers about the progress and results of testing. This establishes the necessary close proximity between development and testing, and achieves high efficiency in the development process. We facilitate this technically, among others, via VPN or cloud-based access to the monitoring system at the testing facility. This way, findings can flow directly back into the development process without any delay. Experienced project managers look after prioritizations and adaptations in the testing program, or even the necessary reporting.

In both stationary as well as mobile use, batteries play a key role in the transformation process in the energy and mobility sector. Advances in innovation and the broad spectrum of applications for batteries are leading to increasing but simultaneously differentiated needs for validation services through which our customers can guarantee a high standard of quality for their products.

Batteries can be tested for environmental influences as well as mechanical and electrical loads in our testing centers as part of the in-house development process for lithium-ion batteries.

Our testing facilities include:

• High-voltage battery testing centers: We test the behavior of high-voltage batteries operating under a wide range of climatic and electrical conditions all the way from the module level to hybrid batteries for purely electrically operated vehicles.
• High-voltage workshop: We construct batteries in our high-voltage workshops as an integral part of development projects. Naturally, this also includes the necessary documentation and “beginning-of-life tests”. Once testing is completed, the batteries can be deconstructed, and the condition of each individual (sub-) component is documented.
  In addition to our extensive expertise in battery development, we are also capable of evaluating the condition or ascertaining potential areas of optimization in the design.
• Testing systems for 1,200 V/1,200 A: Our multi-channel testing systems allow us to test multiple batteries in an (energy-) efficient way, as well as to achieve very high electric power outputs. Comprehensive safety concepts ensure safe operation, but also protect the test specimens.
• Tests for structural strength: We conduct numerous individual tests in order to achieve the goal of operationally reliable and crash-safe batteries. Here, the focus is on the type of battery typical for passenger vehicles and integrated in the vehicle structure, and on the design of battery housings, structural elements, and mounts.
• Capacities for large-scale projects: Bertrandt has sufficient capacity for even large-scale projects with long durations. We look after the validation of batteries throughout all prototype phases and accompany the entire development process right to the start of series production.

Examples of projects in the high-voltage battery area:

• The challenge of fatigue testing: We conduct verification and validation tests on high-voltage batteries, studying their thermal aging and cycle stability in the process. The test durations calculated here of up to twelve months or more in some cases require a high degree of reliability from the testing equipment as well as fully-automated testing procedures. When operating the testing systems, we draw upon our knowledge of the components as well as our many years of experience. This means that our customers can profit from reliable planning for their development projects.

Reliable charging solutions are crucial for operating electrically-powered vehicles. For this, we offer validation solutions for all components involved in the charging process, such as onboard chargers, charging ports, cable sets and plugs, as well as the charging station itself. Here we take into consideration both the functional/electrical aspects as well as the environmental aspects and the resulting aging behavior. 

• Charging tester for functional validation:  With our modular testing equipment, we are capable of testing the standards-compliant behavior of the system components as well as project-specific requirements. Here, the behavior of the vehicle (EV) can be tested and the charging station (EVSE) simulated, or the charging station itself can be the test specimen.  The behavior of a real vehicle and a real charging station can be analyzed in the “man-in-the-middle” setup. In doing so, we work, for example, with DIN SPEC 70121 or ISO 15118.
• Environmental simulation: To confirm the lifespan of all components involved in the charging process, we conduct testing in our labs under temperature, moisture, or mechanical loads. In doing so, we also develop specific measuring and automation techniques to ensure a maximum yield of information is achieved for the development process.

Validation alone falls short – improvement of components and systems is the objective

Practical experience has shown that the important thing is not just validation, but also the improvement of components and systems. In addition to know-how regarding validation methods, the necessary product expertise, as well as links to other services in the overall development process of the components or the system, are particularly important here. Bertrandt can be relied on to fully satisfy all the requirements requested, precisely in line with the needs of the customer, meaning we are much more than purely a validation partner.

• Know-how for complete systems: Bertrandt is one of the largest development service providers for OEMs and Tier n in the automotive engineering, aerospace, mechanical and plant engineering, electrical engineering, and power engineering sectors. We have years of experience in these industries, and we generate added value for our customers by combining the different fields in a targeted way.
• Rapid project implementation: Our services already come into play with the preparation of requirements-based testing specifications. Thanks to our experience in testing methodologies, technologies, and procedures, we can successfully achieve a balanced ratio between effort, benefit, and time here or prioritize individual goals to target specific needs. And our scalable testing capacities mean we can specifically handle high volumes and always meet deadlines.
• Close proximity of locations to customers: As one of the largest development partners in central Europe, customers will always find one of our testing locations nearby.
• Know-how for large quantities of data: Our testing involves a high degree of automation. With the high-performance connections of our testing facilities to our storage systems, but also to need-oriented cloud solutions, our customers receive a maximum yield of information from our tests, allowing them to optimize their development processes in the short and medium term.