3-EM-Powertrain Test Rig

© TU Dresden

Functional Description

The powertrain test rig at the Chair of Automotive Engineering, University of Technology Dresden, consists of three high-performance permanent-magnet synchronous motors. One is used to substitute the ICE (Drive) and the rest is utilized to emulate the driving resistance (Wheel machines = brakes). In addition to the gearbox (manual, automated etc.) many other powertrain-related components (e.g. side shafts, flywheels, clutches) can be analyzed. At the moment, following powertrain configurations can be represented: Inline, transversely, longitudinal engine.

As some of many highlights, the test rig features electric motors with extremely low rotational moment of inertia to allow conductance of very sophisticated tests. Namely, there are for instance the simulation of engine torque pulsation and wheel slip.

Furthermore, a DC source is available for supply of electric powertrains as well as emulation of traction battery characteristics (battery simulator).

Field of Study

By usage of this test rig, analysis of different fields of automotive technology can be conducted such as Driveability, service load tests and control strategy/efficiency. Some of the main tests to be carried out are listed subsequently:

• Optimization of gear shift comfort
• Analysis of powertrain-induced longitudinal oscillations in the vehicle
• Tip-In/Tip-Out
• Full-throttle acceleration
• Simulation of engine torque pulsation
• Simulation of wheel slip
• Test cycles (e.g. WLTC, FTP75 etc.)
• Service load replication tests
• Analysis of power efficiency
• Investigation into and optimization of control strategies (for instance urban driving)
• Analysis of novel powertrain components (E-axle, dedicated hybrid gearboxes
• Inverter test: Short-circuit, functional testing, efficiency

Specification

Input-EM:

• Torque
  • Nominal: 450 Nm
  • Maximal: 720 Nm
• Speed
  • Maximal: 10,000 rpm
• Power
  • Nominal: 220 kW
  • Maximal: 352 kW

Output-EM:

• Torque
  • Nominal: 3,000 Nm
  • Maximal: 4,500 Nm
• Speed
  • Maximal: 3,000 rpm
• Power
  • Nominal: 340 kW
  • Maximal: 500 kW

Battery simulation:

• Power
  • Nominal: 250 kW
• Current
  • Nominal: -1.000 … 1.000 A
• Voltage
  • Nominal: 10 … 1.000 V

Detailed Documentation

DE: Detaillierte Dokumentation 3-EM-Antriebsstrangprüfstand

ENG: Detailed documentation 3-EM-Powertrain Test Rig