Test System Development for Electrified Drives

Electric Mobility Put to the Test

Electrified drives are the key to designing the mobility of the future climate- and resource-friendly. For this purpose, we develop tailored test benches for our customers from concept to commissioning and, if required, provide maintenance via individual service packages.

Based on our many years of experience, we identify state-of-the-art solutions and ensure maximum performance and efficiency of our test systems. Our range of customers includes OEMs and system suppliers from the following sectors:

Your Benefits

Tailored solutions

We develop test and measurement technology according to your specific requirements, including special designs. Our portfolio offers scalable solutions ranging from individual modules and component test benches to test systems for complete powertrain configurations.

One-stop provider

Our experts take responsibility for the complete test bench development – from conception and construction to commissioning. We deliver turnkey test systems and take care of their maintenance and further development throughout the entire life cycle. Necessary trainings for maintenance complete the portfolio.

Open architecture

We rely on a flexible and open architecture by using standard components from dSPACE, National Instruments, Vector Informatik, WAGO, B&R, Ipetronik, HBM, Yokogawa Denki, Huber Automotive, LAUDA, CTS and many more.

Comprehensive documentation

We take care of all necessary documents : from the requirements definition over functional specifications to the technical documentation of the test bench. In addition, we prepare risk assessments and CE markings (EU regulation 765/2008) for you.

Our services at a glance

For the evaluation of power electronics components, such as inverters, on-board chargers or DC/DC converters, at defined operating points, we develop test benches with real electric power outputs and coverage of the required temperature ranges.

  • Integration of HV battery simulations with scalable power outputs and voltages up to 1.5 kV
  • Flexible ambient temperature control from -40° C to 130° C, including explosion protection
  • Separate conditioning of test specimens for temperature ranges from -40° C to 85° C
  • Acquisition and evaluation of measurement data e.g. via FlexRay, LIN, CAN, Ethernet or XCP
  • Development of software-based operating concepts for measurement and control processes

For the test and qualification of electric traction units, we provide tailored test benches with scalable equivalent loads and coverage of the required temperature ranges.

  • Integration of HV battery simulations with scalable voltages up to 1.5 kV and power outputs up to 500 kW
  • Installation of powerful load machines with 20,000 rpm and 200 Nm
  • Flexible ambient temperature control from -40° C to 130° C
  • Separate conditioning of test specimens for temperature ranges from -40° C to 130° C
  • Acquisition and evaluation of measurement data e.g. via FlexRay, LIN, CAN, Ethernet or XCP
  • Development of software-based operating concepts for measurement and control processes

In case of our test systems for in-vehicle energy management and charging, we focus on high energy efficiency and automation of charging and discharging processes.

  • Bidirectional HV DC power supply up to +/-1.2 kV and +/-1.2 kA with power regeneration
  • Electrical system dimensioning and design for maximum charging and discharging powers of 400 kW
  • Basic and high-level communication tests e.g. IEC 61851, ISO 15118-2/-3
  • Error simulation for communication and authorization
  • Acquisition and evaluation of measurement data e.g. for performance, acoustics or vehicle data

For complex drive configurations, you can benefit from our comprehensive experience in planning and implementing system test benches. Even specific solutions, such as climate chambers or special mechanical setups are not an obstacle for us.

  • Requirements analysis and development of test bench concepts
  • Integration of energy supplies for voltage and power control
  • Implementation of temperature control circuits and test specimen conditioning
  • Acquisition and evaluation of measurement data e.g. via FlexRay, LIN, CAN, Ethernet or XCP
  • Integration of safety technology and high-pressure water spray extinguishing systems
  • Development of software-based operating concepts for measurement and control processes
  • Development of solutions for optimizing set-up times and handling of test specimens

You can rely on our turnkey modules for safety monitoring and power supply to develop your test benches, laboratory setups and to conduct vehicle tests.

Product Function

Safety monitoring

 
  • Monitoring of HV systems up to 1.5 kV and 1 kA
  • Monitoring of insulation resistances, voltages and door states (access protection)
 
Power supply  
  • Scalable feed-in power up to 400 V, 63 A, 50 Hz and three phases
  • Compliance with all relevant functional and safety requirements (e.g. emergency stop)
  • Integrable into test benches or laboratory setups
 

Self-sufficient energy supply

 
  • Storage capacity 100 Ah, maximum current consumption 40 A
  • Output voltages 12,8 V, 230 V
  • Easy integration into the vehicle due to different shoring sizes (compact or mini)
  • Reduction of measurement distortions
 

Our services go far beyond the delivery of the test benches. To ensure that your test systems may be used efficiently and sustainably, we offer solutions for the support and operation of the test technology throughout its entire life cycle by our experienced staff.

  • Maintenance, repairs and recalibration
  • Test bench expansion and modernization
  • Commissioning and library development for test automation tools of all common suppliers
  • Development and commissioning of real-time simulation models
  • End-to-end test operation (test specification, automation, execution and evaluation)

Your Contact

Christian Bohner

Head of Department Electronics & Virtual Testing Solutions

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