In this family of test rigs testing loads are exerted by means of e-Machines (dynos) driven by low voltage AC converters coupled through a central supply infeed and a common DC bus allowing energy to be exchanged between e-Machines that are motoring and generating. In this way, energy is saved, the line infeed is relieved, and harmonics reduced.
Additional battery simulator can be provided (DC-DC converter feed from the DC bus). Up to five e-Machines arrangeable in different configurations (e.g. set onto T-slotted bench on vibration isolation air bellows); either of them driving and braking (either acting as motor or generator) and working jointly or separately in a fully flexible way.
Loading torques in both directions while spinning in both directions as well (4-quadrant operation) are intended to conduct both durability tests (endurance, gear tooth scoring…) and functional tests (efficiency, clutch mapping, gear whining, NVH-mapping…) on many powertrain components such as Differentials (LSD, LUD, FRRD), Transfer boxes (PTU, FDU, RDU), Active powertrain components (ETM, EMCD), eDrives / eAxles, etc.
Typical performance of these e-Machines for standard configurations:
- Rated / peak power 490 / 590 kW
- Speed up to 9000 rpm
- Torques up to 9000 Nm