Testing of the electric drive train

Dual performance test bench.
© Fraunhofer IFAM

Dual performance test bench.

Fraunhofer IFAM possesses its own dual engine test rig. In order to intensively investigate electric drive concepts, the Electric Drive Systems Department operates a test and simulation area for the electric drive train. On the test rig, all components of the electric drive are constructed and tested in a certified safe environment. This includes power electronics, electromotors and, if necessary, intermediate energy storage as well as the entire steering and control of the drive and the energy supply. In addition, the battery test rig of the Energy System Analysis Department can be used for a complete autarkic analysis of a battery-driven drive system, such as can be found in automobile or agricultural technology.

Simulation area for the electric drive train

Test bench control center.
© Fraunhofer IFAM

Test bench control center.

With the help of a test and simulation area, the electric drive train is tested under real-world load profiles. Both the entire train and individual components can be tested, evaluated and optimized. As the motor test rig comprises two equal parallel test trains, it is possible to test e.g. two wheel hub motors simultaneously, so that a complete drive axle can be represented as a model.

Technical data for the dynamometer

Electric characteristic values

  • Total power 120 kW
  • Power range ±600 ADC
  • Voltage range 10 – 1000 VDC

Mechanical characteristic values

  • Maximum motor torque 500 Nm (continuous) 600 Nm (short-term)
  • Maximum engine revolutions 8000 U/min (gearless)
  • Maximum battery weight 500 kg

Motor testing

  • Simultaneous testing of two motors
  • Energy recapture
  • Field bus compatibility (CAN, CANopen, FLEXRay)
  • Real time date capture for HiL control simulation as well as control of the drive and the energy supply

Battery testing in a separate test container

  • Testing in the safe area according to EUCAR level 7
  • Conditioning of well-defined loading and aging conditions
  • Defined temperature loads of -40 °C to +140 °C
  • Motor feed through a battery or a battery simulator