OEMs and suppliers are developing new propulsion system concepts, transitioning from traditional transmission technologies (manual, automatic, dual-clutch) to fully electrified powertrains. Electric drives and high-voltage components are now central to this shift.
To support development and system integration, customers require testing systems that not only evaluate mechanical subsystems but also optimize high-voltage electrical subsystems. These testing solutions ensure that both mechanical and electrical components are seamlessly integrated, enabling efficient and reliable performance in modern powertrain designs.
Vehicle Powertrain Testing
Our vehicle powertrain test system enables full-vehicle testing under realistic environmental and driving conditions – with high precision, repeatability, and maximum operational flexibility. It supports energy flow analysis, thermal strategy validation, and efficiency optimization for both light- and heavy-duty vehicles. From early testing to final vehicle integration, AVL provides the tools to accelerate electric vehicle development with confidence and reliability.
Powertrain Tilting Testing
Powertrain Tilting Testing enables realistic validation of hybrid and electric powertrains by bringing road gradients, driving resistances, and optional climatic conditions into the laboratory. The dynamic two-axis tilting approach ensures high precision, repeatability, and safe operation while closing the gap between lab testing and real-world use. It supports the analysis of efficiency, recuperation, and thermal behavior, enabling earlier validation, fewer prototypes, and faster development of robust powertrains.
Powertrain NVH Testing
Our NVH solutions for powertrain testing precisely measure noise and vibration under real-world conditions. Using two or four dynamometers, dynamic loads are applied to the powertrain, with dynos placed outside the NVH chamber to ensure a quiet environment. This setup allows accurate testing of noise and vibration behavior, providing detailed acoustic analysis of powertrain components. Optimize driving comfort and performance with our reliable NVH testing solutions.
Copper Car Testing Method
AVL Copper Car TS™ is a highly realistic test environment for validating vehicle electrical systems and their software. By combining real ECUs, original cable harnesses and precise emulators, the system enables full-power testing at HiL speed. This ensures high test coverage, reproducible results and efficient validation across the entire vehicle lifecycle. At the same time, system-level effects can be identified early and development risks can be mitigated.
Performance Testing
Advanced powertrain performance testing ensures optimal performance for light-duty and heavy-duty vehicles. For light-duty, our systems use two or four dynamometers delivering 3,200–7,000 Nm of torque and 220–500 kW of power, with a battery emulator up to 1,000 kW. Heavy-duty testing employs dynamometers providing up to 40,000 Nm of torque, with matching transmissions when needed, and a 1,000 kW battery emulator. Both setups use advanced simulations for precise, real-world performance evaluation.
Our modern powertrain test systems are designed to validate all types of propulsion systems, including 2WD, 4WD, and electrified powertrains. They support a wide range of speeds, torques, power classes, and voltage and current levels. The dynamometers simulate real-world driving conditions, road data replication, or time-lapsed testing, providing precise speed and torque control. AVL's optimized hardware and software toolchain significantly accelerates the design and validation process, allowing for early testing in a virtual environment (frontloading).
The AVL PUMA 2™ automation software enhances the system by synchronizing measurements from all devices, ensuring high data quality. This precision, combined with the system’s measurement, control, and simulation capabilities, allows customers to perform real-world driving maneuvers and energy consumption tests without needing a physical vehicle. As a result, propulsion systems can be developed more efficiently, reducing development time and increasing overall project success.
Propulsion system architecture and components have evolved rapidly in recent years, leading to new challenges and opportunities. AVL continues to provide tailored solutions that enable our customers to focus on development with confidence, knowing their measurement results are accurate and reliable."
– Reinhard Merl, Global Business Segment Manager, AVLList
AVL powertrain system testing solutions are built on innovative, proven technologies, from dynamometers supporting various power classes to automation software that adapts to a wide range of applications. Our deep application expertise and system integration capabilities drive efficiency for our customers.
We provide the perfect powertrain testing solution tailored to your specific needs, whether it’s for performance optimization, durability testing, or the integration of complex high-voltage components.
AVL Test System Automation – Brochure
Tailored Software Solutions for Future-Proof Test Environments.
AVL’s comprehensive worldwide network of experts allows best customer vicinity, ensuring consistent and connecting testing fields globally. Wherever your R&D challenges take you, we are always close at hand, ready to provide the service you need.
> 70
years of experience
> 5,000
employees worldwide for testing solutions
> 30
countries covered by the global network
> 7,000
testbeds installed worldwide
> 80
turnkey projects
In this recording, Klaus Pfeiffer introduces AVLs latest test solutions for e-powertrain, e-axle and vehicle on e-powertrain.
Join our free webinar to learn how AVL leverages innovative methods for vehicle development and integration to cut testing time in half, move battery validation to the lab, and use AI strategies to save costs. Sign up now to discover more!
In this free, 60-minute webinar, experts from AVL explain how to use optimized test systems to overcome the most significant e-axle and powertrain challenges and shorten development time.