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Performance bench: System test to monitor and evaluate electric vehicles and related components

Country of Origin: Germany
Reference Number: TODE20200304003
Publication Date: 30 March 2020

Summary

A German SME specialised in cross sectoral design and prototyping of highly dynamic test benches and related technology seeks partner from industry or research to develop new applications for test benches in the field of single & multi-track-electric vehicles and its components.

The SME offers a range of highly dynamic, adaptive and scalable test systems that are built on industrial standards. Cooperation is envisaged in terms of research or technical cooperation agreement.

Description

A German SME develops, designs and manufactures – across industries- tailor-made and highly complex custom testing devices for electromechanical components and systems. 



Particularly, in the field of electromobility, the company supports customers with test systems for single and multi-track electric vehicles, such as pedelecs, eScooters, Segway or eQuads, but also their individual components such as drives, transmissions, batteries or communication systems. Thereby, the focus is on electro-mechanical aspects of product development with the associated quality assurance. 



In concrete, the German SME offers a highly dynamic, adaptive and scalable system test that grows with the customer’s needs along the value chain. Due to short development cycles are the indicators to demand a high degree of flexibility during testing and verification. In addition, an upgrade is available according the following test: component testing, Hardware-in-the-Loop testing and End-of-Line testing.



Most important indicators within all phases of development of electric bicycles are quality and safety. System tests are compact and built on industry standards. This allows it to perform a reliable and comprehensive review and analysis of quality requirements and applicable safety standards of e-bikes, pedelecs and S-pedelecs. 



Numerous patent applications and prices confirm the quality of work.



Range of Application:

•	Determining the Range/Efficiency Measurement

•	Check of support performance to EPAC-Norm

•	Determining of the power curve

•	Investigation of overheating behaviour under high load (driving up hill)

•	Fatigue strength of all components before series start

•	Test for quality assurance/ Research & Development

•	Implementation of dealer/customer feedback

•	Verification & Assurance of safety standard DIN EN 15194

•	Hardware-in-the-loop validation of components



Deployment Scenarios:

•	Full automated End of Line System test

•	Checking the safety standard of external assemblies

•	Laboratory and Development Tests

•	Hardware-in-the-Loop System Test with CAN-bus Analysis



The SME seeks partners from industry or research institutions who are interested to work commonly on new concepts in the field of e-mobility (single & multi-track electric vehicles/ components) or applications for test benches. Cooperation is envisaged in terms of a technical cooperation agreement or a research agreement.

Advantages and Innovations

Starting from the 1st of January 2020, the test procedure for the energy efficiency changed from R200 to WMTC (World Motorcycle Test Cycle). 



Thus, an adjustment of the test procedure has become necessary. All vehicles, fast pedelecs and e-bikes up to 45km/h, are based on the classes L1e-B, L2e or L6e. In contrast to pedelecs with a limited maximum speed of 25km/h, at which the R200 test was introduced, the WMTC test presents major challenges for test technology.



On the one hand, the test bench must have a high-performance class but also a very large control dynamic, since the test cycle includes frequent acceleration and deceleration/recuperation.

The prototyping chassis dynamometers were designed and developed for these application scenarios. All vehicles up to 45 km/h, according to the L Standard, can be tested. A highly dynamic servo system enables such roller test rig. Of Course, all tests can run according to EN15194, including the R200 test.



Technical Design



Drive:

•	Up to 2100 Watt continuous rated power

•	Up to 200 Nm rated torque

•	Single-sided or double-sided input torque 



Braking characteristics according to 28 inch wheel:

•	2100 Watt continuous rated power

•	150 Nm continuous brake torque

•	200 Nm brake torque (Peak)

 

Measurement frequency:

•	10 ms

•	1 ms for 1 minute for analysis

•	(Scope-functionality)

Stage Of Development

Already on the market

Requested partner

Fields of the activity of the partner sought (industrial and research institutions):

- E-bike or e-scooter manufacturing

- Development facilities

- Development of products 

- Preparation for series production

- Quality control tests



Goals of the partnership:

- New applications for test benches

- Development of test bench for new concepts in the field of single & multi-track electric vehicles and its components