Full powertrain systems test complete drivetrains outside the vehicle, and require roadload and inertia simmulation capability with accurate speed synchranisation of the drivetrain outputs.

Test-cell configurations for full Powertrains vary enormously, from 2/3-motor conventional
transmission test, through to 5 or 6 motor 4 x 4 hybrid Powertrain systems shown above.
The full powertrain test stand includes adaptable AC dynamometer modules to accommodate
the various architectures under test; conventional engine input is included or replaced by a
further AC machine module. The complete system subjects the powertrain to defined operational
cycles including ‘Real World Simulations’ and the robot driver operates the gear selection
according to required driver characteristics.

The operation of complex hybrid full powertrain cells requires the inclusion of sophisticated
sub-systems including:

• vDriver ‘Real World’ Route & Traffic simulation and driver profiling
• Interfacing to standard emission systems
• Host control
• Vehicle pedal and ‘Real World’ gear-change actuation and simulation
• Specialised Invertor Systems for multiple hybrid and electric-drive motors
• Power Analysis Equipment

The schematic below shows a typical test-cell layout suitable for powertrain test of ‘full’
Hybrid system:

Vehicle Motor Inverters:

Typically a manufacturer will need to test a range of hybrid and electric-vehicle powertrains.
Predominantely, this requires a range of electric motors to be tested within the same testcell.
We have developed sophisticated control software integrated with the world’s leading
invertor technology to perform these demanding applications.

Battery Simulators:

Battery simulators can be provided in configurations to suit the range of vehicles to be
tested in the cell.

Robot Driver:

Our ‘Robot Driver’ system, capable of rapid set-up, self-learns the range of manual and automatic
gearboxes it will be presented with. It provides a test cell with repeatable cycles, class-leading
response times, and real-world simulated conditions when used in conjunction with the vDriver
product. We have been designing robots for over 25 years and they are seamlessly integrated
with our cell control-systems.

Ancillary Equipment:

We have designed modular supporting ancillary equipment, to suit a wide range of engines,
drive-couplings and transmissions. These include:

• Drive shaft systems
• Isolated base plates for test bed components
• Engine mounting systems
• Pallet systems

• Universal Engine & Transmission mounting options
• Oil and water conditioning systems
• Fuel conditioning and flow measurement
• Full data aquisition and data analysis packages

vDriver:

‘Real World’ is becoming an essential part of Powertrain testing, to ensure that the product
will perform as expected in demanding conditions globally. This is particularly important
where the complex strategies of the latest powertrain systems have to accommodate varying
and interactive circumstances and still perform and control effectively. Our vDriver platform
can simulate the variability associated with particular driving styles and routes taken from
around the world. This solution reproduces them repeatably in the test-cell, and includes full
traffic and road-hazard simulation.

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