Test Systems for E-Mobility

In a League of Their Own for the Future of Mobility

Electromobility is one of the biggest trends in the industry today. That not only results in changes to components and drives, but also brings with it completely new demands for test benches used to test e-mobility components.

Our e-mobility test rigs are real all-rounders: they can test entire drive axles as well as electric engines, and electric axle drives without an engine. Even conventional components for passenger cars can be tested on our e-mobility test benches.

ZF offers End-of-Line as well as R&D test rigs for electromobility. Each of our test benches is unique: thanks to their modular design, we can react flexibly to special requirements and customer requests.

The e-mobility test systems by ZF stand out from regular engine and transmission test benches mainly thanks to their high speed which can reach up to 26,000 rpm. They also factor in geometrical characteristics of e-axles and can deliver up to 750 kW power and 1,200 Nm torque.

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R&D E-Mobility Test Bench with Adjustment Table

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The new ZF TS edIN

The automated EoL test bench for series testing of electric drive axles impresses with its high flexibility and acoustically optimized machine dynamics.

E-Mobility series test bench “edIN”

The electric drive Investigator (edIN) is designed to operate in a fully automatic End-of-Line test field environment as well as a semi-manual operated single test bench (e.g. prototype or conformity of production test purpose).

During the development of this new test bench concept, special emphasis was placed on:

acoustic behavior including simple and rigid clamping concept
high flexibility regarding NVH measurement methods (linear, laser or torsional sensors)
minimal test sample change times
fully or partially automated test sample contacting, simple type change, high maximum type variance
easy serviceability and maintenance
integration of additional functions for handling-activities like sensors (e.g. linear or laser NVH), components (e.g. plugs) or vision systems (e.g. camera or scanners)

The test bench can be automated with our ZF Test Systems software TESCON or according to customer requirements. Combined with our proven advanced analytics tool "ZF wAIveGuard" we can offer users maximum support through advanced techniques such as machine learning and artificial intelligence.

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R&D Test Bench: Expert for E-Mobility

The R&D e-mobility test bench

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The new ZF Dynamic Road Simulation Test Bench

In order to avoid lengthy, complex and therefore expensive road tests, ZF Test Systems has developed the DRS (Dynamic Road Simulation) test bench. It can be used, among other things, for real-time simulation of driving maneuvers such as starting on snow.

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Road-to-Rig test system. ZF indoor dynamic road simulation test bench for complete vehicles or powertrains.

To always be at the cutting edge of technology, the development time for new vehicles with increasingly complex drive systems must become shorter and shorter for the manufacturers. In the future, this will primarily affect hybrid and e-vehicles.

In combination with the IPG CarMaker software, the DRS test bench is a useful investment for automotive manufacturers and development service providers.

Key Target: Drivetrain application software development

Repeatable conditions
CO2 improvement
Time saving
Automated
Even w/o vehicle by means of car models

Key Achievements:

Real-time simulation of longitudinal driving maneuvers
Dynamic simulation of tire and its grip situation
Closed loop control >10 kHz for wheel/slip simulation
Virtual vehicle dynamics in the loop by IPG

Purpose / Advantage:

Verify and develop drive control software in and after V-cycle
Verify transient acoustic behavior
Find failures (NVH, shifting up, down, backlash, software setting, assistant systems)
Simulate extreme conditions (snow dig out, tire slip, brake control systems match torque vectoring etc.)
Safe time on rare prototypes
Independent from driver and weather, repeatable laboratory conditions
Efficiency cycle w/o influence from tires and wheels
Development and calibration of vehicle and simulation models

Test systems for a broad range of applications

Electric engines can be tested in addition to entire electric drive axles. The e-mobility test system also allows for passive testing of electric axle drives without an engine during the development phase. Owing to its modular design, the test rig can also be used to test conventional passenger car transmissions. Our e-mobility test bench is thus in a league of its own.

With the new e-mobility test bench by ZF electric engines can be tested in addition to entire electric drive axles or electric axle drives without an engine.