Electric Powertrain Systems for E-Motor and Electric Driveline Testing

ACS engineers, integrates, and builds AC and PM (permanent magnet) dynamometers and dyno control systems for e-drivetrain development and electrified powertrain and component testing. Depending on your needs and the Unit Under Test (UUT), we can supply complete dynamometer systems including motors and riser bases, guards, torque transducers, connection cables, battery simulators, UUT power supplies, power analysis, and high voltage interface panels in single- or multi-axis configurations. The systems can be assembled and integrated into a test cell, built as a complete, stand-alone test stand, or integrated as part of an in-process or end-of-line manufacturing test station.

We will work with your team to define and implement a dynamometer testing solution that meets your requirements. To help you get started, we’ve developed a specification questionnaire.

Dynamometer Questionnaire

Application Areas Include:

  • Production testing of transaxle and drive motor systems
  • Electrified axles, gear boxes, transmissions, accessories
  • Component and system development and performance verification
  • Electric ground-vehicle and aerospace powertrain testing
  • Powertrain control system and inverter development

E-Motor, E-Axle, and Electric Powertrain Dyno Examples

electric powertrain systems, electric motor dynamometer

Integrated Test Cell

This example consists of two 125kW/2000Nm/600RPM base speed AC-dynamometers that are connected to the output shafts of an e-transaxle test unit.

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  • High-torque quad-dyno for full vehicle, chassis, or skateboard; dual-dyno for e-axle; or single-dyno for large e-motor test units
  • Complete systems including air-cooled or water-cooled dynamometer motors and riser bases, bedplate, drives, guarding, torque transducers, high-voltage power supplies or battery simulators, controller, data acquisition, and interconnection cables
  • Optional measurement and conditioning features including high-voltage/high-current/power measurement and analysis, finite element driveline analysis and vibration monitoring, acoustic/NVH enclosures, thermal conditioning chambers, UUT fluid conditioning, and HIL (hardware-in-the-loop) interface
  • Driveline and risers designed for flexibility and/or speed of UUT hookup
  • ACS Framework open-source control system built on NI™ LabVIEW software
  • Power, speed, and torque capacities of dynamometer, drive, and battery simulator sized to meet customer requirements with off-the-shelf or custom-designed components
electric powertrain systems, electric motor dynamometer

Stand-Alone Integrated Test Stand

This example consists of a 5kW/12Nm/11,000 RPM max speed AC dynamometer for small e-motor testing. Also fully integrated into the test stand enclosure are the drive, high voltage power supply, UUT power measurement and analysis, and data acquisition and control system.

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  • Compact integrated test stand designed that contains all measurement and control equipment, with a single 480VAC power feed
  • Low-inertia dynamometer motor and driveline accommodates a wide range of high-speed electric motors and power systems
  • Complete systems including air-cooled or water-cooled dynamometer motors, UUT mounting fixtures, drive, guarding, torque transducer, high-voltage power supply or battery simulator, controller, data acquisition, and UPS (Uninterruptible Power Supply)
  • Optional measurement and conditioning features including high-voltage/ high-current/power measurement and analysis, finite element driveline analysis and vibration monitoring, acoustic/NVH enclosures, thermal conditioning chambers, UUT fluid conditioning, and HIL (hardware-in-the-loop) interface
  • Driveline and UUT fixture designed for flexibility and/or speed of UUT hookup
  • ACS Framework open-source control system built on NI™ LabVIEW software
  • Power, speed, and torque capacities of dynamometer, drive, and battery simulator sized to meet customer requirements with off-the-shelf or custom-designed components
electric powertrain systems, electric motor dynamometer

E-Motor Dyno Options and Additions

This example consists of a 37kW/34Nm/10,000 RPM max speed AC dynamometer for e-motor testing and is capable of high acceleration testing up to 20,000 rad/s. The fully integrated test stand enclosure also incorporates the dyno and UUT coolant conditioning system required for testing and operation.

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Cooling Options for Stand-Alone Integrated Test Stand

  • For applications that require liquid cooling of the motor or other UUT, the test stand can be customized with an integrated or stand-alone oil and/or coolant conditioning, circulation, and measurement system. Some example specifications for this system include:
    • Variable, user configurable flow path to unit under test
    • Mobil EC Cooldrive Elite working fluid
    • 12-20 micron working fluid filtration
    • -20°C to 130°C to controlled fluid temperature to UUT
    • 0 to 700 kPa controlled fluid pressure to UUT
    • 0 to 30 LPM controlled flow rate to UUT
  • Integrated test stand for electrification testing contains all measurement and control equipment
  • Dynamometer motor and driveline accommodates a wide range of high-speed and high-acceleration electric motors and power systems
  • Complete systems including air-cooled or water-cooled dynamometer motors, UUT mounting fixtures, drive, guarding, torque transducer, high-voltage power supply/battery simulator, controller, data acquisition, and UPS
  • Optional measurement and conditioning features including high-voltage/high-current/power measurement and analysis, finite element driveline analysis and vibration monitoring, acoustic/NVH enclosures, thermal conditioning chambers, UUT fluid conditioning, and HIL (hardware-in-the-loop) interface
  • Driveline and UUT fixture designed for flexibility and/or speed of UUT hookup
  • ACS Framework open-source control system built on NI™ LabVIEW software
  • Power, speed, and torque capacities of dynamometer, drive, and battery simulator sized to meet customer requirements with off-the-shelf or custom-designed components
electric powertrain systems, electric motor dynamometer, electric motor spin test

Motor Spin Test Stand

This example consists of a 21kW/60Nm/18,000 RPM max speed AC dynamometer for small e-motor spin testing. Among other things, it can be designed for motor back EMF testing, mechanical spin testing, short circuit thermal testing, and resolver wobble testing.

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  • Compact integrated test stand contains all measurement and control equipment, with a single 480VAC power feed
  • Low-inertia dynamometer motor and driveline accommodates a wide range of high-speed electric motors and power systems
  • Complete systems including spin dynamometer motor, UUT mounting fixture, drive, guarding, torque transducer, short-circuit contactor, controller, data acquisition, and UPS (Uninterruptible Power Supply)
  • Optional measurement and conditioning features including high-voltage/high-current/power measurement and analysis, finite element driveline analysis and vibration monitoring, acoustic enclosures, thermal conditioning chambers, UUT fluid conditioning
  • Driveline and UUT fixture designed for flexibility and/or speed of UUT hookup
  • ACS Framework open-source control system built on NI™ LabVIEW software
  • Power, speed, and torque capacities of dynamometer, drive, and short circuit load sized to meet customer requirements with off-the-shelf or custom-designed components
electric powertrain systems, electric motor dynamometer controls

Controller for E-Motor and Electric Powertrain Dynos

ACS provides dynamometer test stand or test cell control with a customizable hardware and software system that is built on the open-source ACS Framework

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  • NI™ real-time PXIe controller and chassis coupled with customizable IO configurations
  • Controller enclosed in a configurable 19” rack-style enclosure that houses the user interface PC
  • System monitors can be affixed to the rack or provided with an optional worksurface
  • Connectorized panel or interface box can be provided if the control area is not adjacent to the test unit
  • Optional communication modules for interfacing with third-party controllers and devices over Ethernet I/P, EtherCAT, CAN, ProfiNET, Modbus, etc.

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