E-Axle and E-Drive Test Bench

JKT E-Axle and E-Drive test benches are designed to meet the testing requirements of various electric axles and electric drive assemblies. It can accurately simulate real vehicle driving conditions and various actual operating conditions of the unit under test (UUT). It supports comprehensive tests including steady-state/dynamic performance, durability, NVH, transmission efficiency, differential performance, control strategy calibration, as well as reliability and durability under extreme environments. Key parameters such as torque, speed, efficiency and temperature rise can be measured precisely to identify potential design flaws and performance bottlenecks in advance, avoid safety risks and economic losses, and improve testing accuracy.

The JKT transmission and reducer test bench is equipped with a precise and reliable mechanical system, a highly dynamic and stable control system, and powerful software packages.

JKT provides customers with both transverse and longitudinal transmission test benches, which can be applied to various vehicles such as passenger cars, commercial vehicles, heavy-duty trucks and off-road machinery. The transverse transmission test bench features an extremely small wheel center distance, making it suitable for testing extremely compact transmissions in battery electric vehicles and hybrid vehicles. JKT has designed a test bench that can handle both coaxial reducer testing and conventional reducer testing, based on the characteristics of coaxial reducers and general reducers.

1.1. Model Selection of Drive and Load motor

Wheel-side loading motors are used to simulate wheel-end loads, and dynamometers can be selected according to test requirements. If low moment of inertia dynamometers are needed, permanent magnet synchronous motors or customized high-dynamic asynchronous motors can also be adopted.

Load Motor Parameters for E-Axle and E-Drive Test Bench:

Note: Environmental chambers are optional for E-Axle and E-Drive test benches.

JKT can provide customized products according to customer requirements.

1.1. MAIN TECHNICAL PARAMETERS

• Torque measurement control accuracy：±0.05%FS

• Speed sensor pulse resolution：1024/600pprppr

• Torque control accuracy：±(0.5~1)%FS

• Speed control accuracy：±(0.01~0.05)%FS

• The max vibration value of dynamometer（RSM）：≤2mm/s（no load）

• The bearing support temperature rise：≤35℃

• The max vibration value of the bearing support（RSM）：≤2mm/s（no load）

• DAQ sampling rate：1kHz

• Current measurement channel:4/6

• Voltage measurement channel:4/6

• Measurement accuracy of power analyzer: ±0.05%

• Temperature sensor measuring range: -50℃~200℃

• Measurement accuracy of temperature sensor: A class

• Vibration sensor measuring range: 0~20mm/s

1.1. Typical Application Project for E-Axle and Powertrain

Test benches test electric axle or electric drive of the electric vehicles (EVs).

Main test contents:

• Efficiency test

• Torque test

• Speed test

• Differential test

• Temperature rise test

• Over-load test

• Steady-state test

• Maximum speed test

• Durability with temperature climate test

• CLTC/WLTC cycle condition test

• User-defined cycle condition test

• Controller calibration test

• Road load simulation test

• Accelerated response test

• Torque response test

• NVH test (option)

 

Basic configurations:

Dynamometer & Mechanical System: Two high-dynamic asynchronous motor are selected as the load motors, equipped with a high-speed drive shaft system and precision, reliable mechanical components. Each load unit can be moved along the axis direction for different UUT.

 

Frequency Converter: Four-quadrant frequency converters are adopted for dynamic or steady-state control of the dynamometer. It enables control of rotational speed, torque, allowing the dynamometer to operate in either motoring or generating mode.

 

MCU Power Supply: Provides an adjustable low-voltage power supply for the motor controller.

 

Test Object Cooling System: Supplies cooling medium for the tested E-axle and E-drive. An oil or water-cooling system is available for certain oil-cooled or water-cooled test pieces. Parameters including temperature, pressure and flow rate of the cooling system are fully adjustable. The water-cooling system can also use ethylene glycol as the cooling medium.

 

Climate Chamber: Provides a simulated operating environment with controllable high/low temperature and humidity for the test objects.

 

Automated Measurement & Control System: Conducts overall control and condition monitoring of the entire motor test bench.

E-drive(Powertrain) test bench (400kW 4000N.m 3000rpm)