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:

Automotive
Aerospace
Industry and recycling

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 test bench 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 the necessary documents: from the definition of requirements to functional specifications to the technical documentation of the test stand. In addition, we prepare the risk analysis, risk assessment and CE marking for you in accordance with EU Regulation 765/2008.

Our services at a glance

Modular inverter and converter test benches

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

Test benches for electric motors and e-traction

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

Battery test benches

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

System test benches

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

Turnkey modules for electric mobility test benches

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
Bertrandt HV Safety Guard – Safety monitoring	Monitoring of HV systems up to 1.5 kV and 1 kA Monitoring of insulation resistances, voltages and door states (access protection)
Bertrandt Scalable Power Distribution Unit – 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
Bertrandt Power Companion – 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

Lifecycle management

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)