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3-drive test bench HAP02

Function and layout

Configuration 1: Test rig for electric drive system
The electric drive system is supplied by a battery simulator. It drives a
flywheel mass via connecting shafts on each output side. Two electric
motors simulate vehicle speed and dynamic load.

Configuration 2: Electric motor test rig
The electric motor is supplied by a battery simulator.
The output side of this electric motor is coupled to an electric load motor via a transmission with various ratios. This simulates the vehicle speed
and dynamic load.

With a controllable electric load the low-voltage system of the test sample can be tested if requested.
 

Configuration 3: Test rig for gearbox or transmission

One electric motor drives the input side of the test sample (test axle, gearbox).
Each output side is coupled to an electric motor.
These electric motors can simulate the vehicle speed and the dynamic load.

A water cooling system exists to supply cooling of the test sample.
  

 

Technical Data 1.1

 
Drive side:test sample (electric motor with or w/o integrated transmission)
Electric Motors coast side: 2 aircooled DC motors SIEMENS GC2810 with flywheel each
 max. power input:124 kW each
 max. torque input:1800 Nm each
 max. speed:2000 rpm

  

Technical Data 1.2

 
Electric motor drive side:

DC electric motor type Siemens 1GC5, air-cooled, with belt transmission (ratio 1:1 or 1:2 or 1:3)

 max. power output:215 kW
 max. torque output: 733 / 366 / 244 Nm
 max. speed:7000 / 14000 / 21000rpm
Electric Motors coast side:2 aircooled DC motors SIEMENS GC2810 with flywheel each
 max. power input:124 kW each
 max. torque input:1800 Nm each
 max. speed:2000 rpm
 

Technical Data 2

Electric power supply:battery simulator, type Kratzer VES 150/500/500
 max. power:+/- 150 kW
 voltage:10 – 500 V
 current:+/- 500 A
 battery model:three implemented models,
further models are programmable
 communication:via CAN-Bus / Profibus DP
Electrical load:Zentro-Elektrik EL 3000/400/250
 load power:3000 W
 load voltage:2,5 up to 400 V
 load current:0,01 up to 250 A

 

Possible Set-ups

Testing of front or rear axle electric drive units
Testing of longitudinal rear wheel (RWD) drive trains
Testing of front or rear wheel differential gearboxes
Testing of FWD drive trains

 

Testing purposes

Endurance tests based on real road data
Functional tests of drive units (end-of-line tests, power wasting tests)
Functional tests of drivelines and driveline sub-systems
Simulation and testing of different battery models
Run-in of gearboxes and differentials
NVH investigations on drivelines and components

 

Operating methods

Manual operation
Automatic operation controlled by hofer software PLS (e.g. ramp functions)
Endurance test operation based on real road data (24 h operation)

 

Measurement technology

Torque measurement (input and output side)
Speed measurement (input and output side)
Temperature measurement of test sample
CAN bus system for communication with the test sample

Additional measuring equipment if requested 



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