AVL Powertrain TS™

A versatile test system (TS) for validating pure ice and electrified propulsion systems.
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AVL Powertrain TS™ is designed to help you manage the complex validation of ICE-driven vehicles and electric vehicles (EVs) – hybrid EVs, plug-in hybrid EVs, battery EVs, and fuel cell EVs – throughout the development process.

We have a wealth of experience in the development of propulsion system test systems for passenger cars, light and heavy-duty trucks, busses, tractors and off-road vehicles. We provide solutions for the entire development process. These solutions can be applied to a wide range of applications. Typical examples of propulsion system tests are durability testing to ensure specific lifetime targets of propulsion system components, performance evaluation, optimization of consumption, emission and electrical driving range, drivability optimization, as well as integration of HV components, on-board diagnostics, and failure diagnostics where safety-critical tests are conducted to check if unforeseen interactions result in undefined operating conditions. 

OEMs and suppliers are developing components and systems for new propulsion system concepts. In the past this was mainly driven by transmission concepts (manual, automatic, and double clutch transmissions) used in 2WD or 4WD propulsion. Today, the propulsion system architecture is completely changing with the shift to pure electrified propulsion systems. Electric drives and other high-voltage components play a central role. For development and system integration purposes, customers need a test system for evaluating and optimizing the mechanical as well as the high-voltage electrical sub-systems.

History

Our modern propulsion test systems are built to validate any kind of propulsion system with different types (e.g. 2WD, 4WD), speeds, torques, and power classes, as well as voltage and current levels in electrified propulsion systems. The dynamometers are speed and torque to the propulsion system, which emulates real-world driving conditions, road data replication, or time-lapsed testing. The optimized toolchain of the AVL hardware and software significantly reduces the duration of the design and validation process. Tests can be executed in an early development phase (frontloading) using the proper virtual environment. This minimizes the risk of design changes in a later stage of the development process.

Challenge

Our AVL PUMA 2™ automation software adds even more value, since the software synchronizes measurements from every device. This high level of data quality – combined with the system’s precise measurement and control and simulation capability – enables our customers to develop propulsion systems within a reduced timespan, by performing real-world driving maneuvers or energy consumption tests without having the vehicle available.

Challenge

AVL Powertrain TS™ – Solutions for every requirement
AVL propulsion system testing solutions are built on state-of-the-art, proven products that range from dynamometers for different power classes, to automation software that supports a wide range of applications. Our application expertise and system integration capabilities increase the efficiency of our customers. We deliver the right propulsion system testing solution for your needs.

  • Performance Testing LD
    Two or four dynamometers with a torque range of 3,200 Nm to 7,000 Nm with an output of 220kW up to 500kW are mounted directly at the wheel hub. A battery emulator with an output of up to 1,000kW typically replaces the battery in an electrified propulsion system. A powerful vehicle dynamics simulation enables driving maneuvers in various driving conditions.
     
  • Performance Testing HD
    Two, four, or more dynamometers with a torque range up to 40,000 Nm are used. Sometimes matching transmissions are necessary to achieve the high torque requirements of the unit under test. A battery emulator with an output of up to 1,000kW typically replaces the battery in an electrified propulsion system. A powerful vehicle dynamics simulation enables real-world driving maneuvers.
     
  • NVH Testing
    Two or four dynamometers are used to load the propulsion system. The dynamometers are installed outside the NVH chamber to achieve the ambient noise.
     
  • System Integration, HV Integration
    The basis for the test system is a highly automated propulsion test system with four high-dynamic wheel dynamometers. It also offers several conditioning devices, load units, and measurement equipment for rotational speed, torque, temperature, etc. Thus, a high number of tests can be executed and repeated in a short time. To address the needs of HV electrified propulsion system validation, the test system is extended with additional testing equipment, such as high-power HV sinks/sources, measurement systems with high sampling rates for voltage and current, and mains emulation.
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Nothing is more constant than change. Propulsion system architecture and components have changed dramatically in recent years. Consequently, use cases and applications have also changed. AVL has always been able to design the right solutions for our customer needs. Meaning our customers can focus on their development and trust their measurement results.”

– Dr. Klaus Pfeiffer, System Line Manager, AVL Deutschland GmbH

Concerto
AVL CONCERTO 5™

With built-in and ready to use domain know-how, CONCERTO empowers data-driven engineers to become a strong development influencer.

e-storage bte
AVL E-STORAGE BTE™

Battery tester and emulator for research and development, testing, and validation purposes.

E-Storage LV
AVL E-STORAGE LV™

Highly dynamic, regenerative power supply optimized for the testing of low-voltage micro and mild hybrid systems.

SPECTRA
AVL SPECTRA™ Wheel Dyno

The SPECTRA converter system is a modular silicon carbide (SiC) converter able to control wheel dynos at unprecedented levels of control accuracy and dynamics thus helping you to test your powertrain with confidence.

Performance Testing LD – typical applications:
•    Propulsion system durability
•    Performance testing
•    Advanced calibration for drivability
•    Failure diagnosis
•    Energy consumption and driving range optimization

Performance Testing HD – typical applications:
•    Propulsion system durability
•    Performance testing
•    Advanced calibration for drivability

NVH Testing – typical applications:
•    Transmission NVH
•    Propulsion system NVH

System Integration, HV Integration – typical applications:
•    Performance testing
•    System integration 
•    HV integration
•    Propulsion system calibration
•    Advanced calibration for drivability
•    Failure diagnosis
•    Energy consumption and driving range optimization

Solutions

Your reliable global partner in powertrain testing solutions

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.

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> 70

years of experience

> 5000

employees worldwide for testing solutions

> 30

countries covered by the global network

> 7000

testbeds installed worldwide

> 80

turnkey projects

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