Highly Efficient
E-Axle Testing
The e-axle combines electrical, electronic, and mechanical
systems in a subsystem – which increases testing requirements.
AVL is familiar with these requirements and provides a highly
efficient complete solution.
odern e-axles are at the core of the propulsion system
Jor electric and electrified veLicles. 8Ley comFine tLe
electric motor, inverter and transmission in a highly
integrated subsystem. This enables e-axles to be integrated
easily in vehicles. However, as a subsystem, they must
safeguard all relevant load situations for individual components.
What does this mean for the test system? The testbed must
enable simple installation of e-axles but does not have to be
designed witL tLe same degree oJ ƽe\iFility as conventional
propulsion systems. There is no need for complex UUT
mounting systems like needed for conventional propulsion
configYration and transmission tyTes, or Jor a Fase Tlate witL
cushioned foundations. With the AVL E-Axle TS™, the two load
units are mounted on a common frame. This is decoupled
from the building with polymer elements, making it suitable
Jor installation on any indYstrial ƽooring. -t is also mYcL more
compact than conventional propulsion system testbeds.
The use of a climate chamber and the corresponding
conditioning systems enables testing at various ambient
temperatures, as required by the testing standards for e-motors
and inverters.
DC units are used for electric supply or load, applying models
to configYre FoYndary conditions tLat mimic realistic driving
situations (with a battery model, for example).
*ocYsing on eƾcient testing tLat continYes to deliver reliaFle
results, the AVL PUMA 2™ automation system and the integrated
AVL EMCON 6™ control Lave Feen e\tended sTecifically Jor
e-axle testbeds. Thus, the high-performance software enables
systematic testing of all components for the e-axle. Speed and
torque are determined and regulated precisely, using a specially
developed regulation procedure. Operation involves specifying
a speed for the load systems and a torque for the e-axle, or in a
vehicle simulation that mimics real operation. For a single-motor
e-axle, the system also controls the speed and torque difference
for the differential. In the case of a twin motor e-axle with two
independent e-motors, both motors and the load system are
controlled independently. In conjunction with clear parameter
FlocOs and oTerating windows, tLese control configYrations Jorm
part of our comprehensive automation solution, allowing AVL
to test ea\le testFeds e\tremely eƾciently in terms oJ time and
costs.
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