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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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.
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 model
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