Testing the drive of tomorrow in the era of e-mobility

Authors

J. Trumpff - GETEC Getriebe Technik GmbH

Summary

Testing the drive of tomorrow is the challenge what we are facing on the test fields today. Reliable products for the e-mobility require a high-end testing.

The speech will give an overview of the different drivetrain configurations which are required due to e-mobility. The configurations are Hybrid, DHT, Plug-In Hybrids and DHTs as well as pure EVs. Especially the pure EVs are using the potential from e-mobility in many different facets: Combining e-axles on the front and rear axle, coaxial drives, dry sump configurations, torque vectoring with two e-motors on the rear axle, extreme high speeds, and much more.

All these various properties require a lot of different configurations for the today’s testbenches. The possible bench configurations will be described within this speech. 1-Dyno for e-motor testing, 2-Dyno for e-Axle testing, 3-Dyno for reducer transmission testing. Beside high-speed dynos, battery simulation systems, water, and oil conditioning, also the vibrations have to be considered. Therefore, new high-tech polymer concrete frames are developed, installed, and tested in GETEC. Calculation and analysis will be introduced within this speech.

Reduced center distances and coaxial drives are challenging the testing as well was extreme requirements on torque of the dynos or the power supply from vehicle energy systems (VES). There is an approach of parallelization from VES.

For testing itself, test programs must be developed. Modify existing programs based on experience is one solution. Road load data can support the test cycle development.

Summarizing the speech in the end will lead to the outlook and potential to upgrade existing test facilities to be up to date for the future.