The demand for testing is highly dynamic, often requiring the urgent expansion of test capacity to meet product development deadlines and market release dates. However, access to capital represents a significant limiting factor. There is a growing reluctance among companies to commit substantial financial resources to long-term investments, particularly when there is no immediate return on investment.
Traditional brick-and-mortar test facilities require extensive time for planning, approval, and construction. The process can take several years, from identifying the need for additional capacity to the point of facility operation. This delay not only extends the time to market but also ties up capital, which limits a company's financial flexibility and responsiveness to market changes.
Extensive Approval Process
Getting the necessary approval for starting construction of new brick-and-mortar test facilities takes a long time.
Low Degree of Parallelization
While the approval process is running, many of the other activities cannot start, increasing the project time.
Commission-ing First at the End
With all coming together first at the construction site, the commissioning can first happen at the end of the project – with potential unwanted surprises.
Low Flexibility to Add Further Test Capacity
Additional space must be reserved in the facility hosting the test system if a later extension is desired.
Challenging Coordination of Suppliers
Building up a new test facility requires coordination of all involved suppliers, requiring experienced test facility project managers.
Lack of Mobility
A conventional test facility is stationary and cannot be moved to another location if later necessary.
Our test systems are available in tech center modules that are quickly up and running. The solution consists of a fully integrated test system in a containerized format. The module can operate independently to a high degree, only requiring a flat surface to be located on and the necessary external power and media connections.
Through standardization, supply chain management and preemptive engineering efforts, we have significantly reduced the time from order to start of operation at the customer site. This provides our customers with optimal flexibility to respond to changing needs and limits their capital commitment.
Tech Center Module – Battery Pack Testing
The battery is the most critical and expensive component of an electric car, truck or any other electrified transport vehicle. Extensive R&D, testing and homologation efforts are essential to ensure battery performance over the life of the vehicle. The demand for testing is highly dynamic, often requiring additional test capacity at short notice. The battery testing module provides a cost-effective and readily available solution for climatic testing of battery packs and modules. Its remarkably short delivery time is made possible by optimising a standardised solution using proven components.
AVL Tech Center Module – Fuel Cell Testing
Hydrogen and fuel cells will play a key role in meeting CO2 reduction targets in industry and transportation. While fuel cell systems are advancing, challenges such as improving durability remain. The need for testing is dynamic, but the planning, approval and construction of new facilities can take years, delaying progress and tying up capital. The Fuel Cell System Testbed Module combines decades of experience in fuel cell development for applications such as automotive, truck, aviation and stationary systems. Its modular design adapts to specific requirements, ensuring compatibility with diverse testing needs.
Tech Center Module – E-Axle Testing
The integration of e-drives and transmissions into e-axles reduces packaging needs and improves efficiency. Validating e-axles requires combining environmental and fatigue testing. Testing demand is highly dynamic, with urgent needs for additional capacity. However, planning, approval, and construction of new facilities take years, delaying time-to-market and tying up capital. The e-axle testing module provides a complete solution for developing, testing, verifying, and validating e-axles, whether single or dual motor setups. With minimized delivery time and competitive pricing, it meets diverse testing needs efficiently.
Tech Center Module – Brake Emission Testing
Future emissions legislation will cover brake wear emissions in addition to the existing limited vehicle emissions. This creates significant R&D, testing and homologation requirements for braking systems. Brake emissions measurement presents new challenges that require specialised expertise and advanced methodologies. Strategies such as regenerative braking are essential to minimise emissions, increasing the need for advanced test bed functionality. The brake emission module meets these requirements, exceeds GTR standards and is ready for testing within a year.
With our Tech Center Modules, we offer cost effective solutions that are up and running in a very short time. It is particularly valuable for customers who needs to act fast on changings needs and where the requirements on the installation location must be kept to a minimum.”
– Stefan Sohar, Solution Engineer, AVL List GmbH
In most cases, a building permit is required to install and operate a tech center module. However, the permitting process for modular solutions is typically faster than for conventional testbeds. This efficiency arises from the clearly defined scope of modular projects, similar to that of a product. A significant advantage is that construction can begin while the permitting is still in progress, saving valuable time and often reducing the project timeline by 3 to 5 months. Additionally, when tech center modules are installed within existing buildings, additional permits may not be required, depending on local regulations.
Tech center modules are engineered for both indoor and outdoor applications, meeting all essential requirements such as air conditioning, humidity control, noise reduction, fire safety, and durability. These versatile modules can be combined into larger configurations or stacked up to three stories high, allowing for flexible space utilization. Furthermore, local building regulations can be satisfied by incorporating a roof or facade, ensuring that the modules blend seamlessly with their surroundings.
For optimal performance, tech center modules must be installed on a leveled and paved surface, such as a pad or screw foundation. Depending on the specific application of the module, essential utilities - including electrical power, compressed air, chilled water, demineralized water, and wastewater - must be provided. If these services are not available on-site, an optional utility module can be supplied to meet the necessary requirements.
Unlike traditional shipping containers, tech center modules are constructed from high-quality, container-like structures specifically designed for easy transport and assembly at their destination. These modular units adhere to stringent standards for insulation, safety, and noise and vibration control. Inside, the seamless design provides users with a high-performance environment comparable to that of a traditional facility.
Tech center modules are available with UL or CE certification, depending on the region and specific customer requirements. These certifications guarantee compliance with safety, health, and environmental standards, whether in North America (UL) or the European Union (CE). This ensures that tech center modules meet the necessary regulations and provide a reliable and secure solution for various applications.
Each tech center module typically measures up to 4.5 meters in width, 15 meters in length, and 2.9 meters in height, with a total weight ranging from 20 to 25 tons, including all technical equipment. It is important to note that specific dimensions and weights may vary depending on the application. For more detailed information, please refer to the solution sheets for each configuration.
For battery (module/pack) testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.
At AVL, we develop e-axle solutions that can be easily installed without impacting the productivity of your engineering facility.
The AVL Brake Wear Testing Solution is an all-in-one testing solution for the measurement of particle mass and number concentration of braking systems using a high-end brake dynamometer.
In the search for green and sustainable mobility, AVL has addressed the challenges of developing and validating automotive fuel cell systems – from a single cell up to complete systems for various applications.
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