he growing diversity of powertrain concepts increas-
es the demand for precise and realistic testing.
Accurate simulation of real-world conditions requires
high-performance media conditioning systems. The new AVL
ConsysActive portfolio provides this capability with efficient
refrigeration circuit control, ensuring precise and energy-effi-
cient testing conditions. The modular product family includes
air, glycol, and oil conditioning units that deliver stable and
reproducible results under steady-state operation.
or a decade, AVL E-STORAGE BTE™ has set the
benchmark in battery pack testing and emulation.
As AVL’s first in-house electrified product line, it
established scalable, precise energy supply solutions for
e-mobility. Today, more than 1,500 channels are installed
worldwide, challenging batteries, e-motors, drivelines,
hybrids, and fuel cells.
Scalable up to 3 MW and 1,500 V, E-STORAGE BTE com-
bines outstanding control accuracy with dynamic perfor-
mance, enabling realistic battery emulation and precise
reproduction of load profiles. Automated configuration
changes minimize downtime and increase utilization, while
0.01 % FS accuracy ensures reliable results. With air- and
water-cooled variants, the portfolio continues to evolve to
meet next-generation testing demands.
After ten years, E-STORAGE BTE remains a cornerstone
of AVL’s e-mobility testing portfolio – delivering precision,
versatility, and innovation for the future of e-mobility.
Precision Climate Control for
Versatile and Sustainable Testing
Energy Flow Testing
the Smart Way
10 Years of E-Mobility
Testing Excellence
Designed with standardized industrial-grade components,
ConsysActive systems combine robust performance with
simplified service and spare parts management. All units are
available with refrigerants below 2500 GWP as well as a CO2
version for environmentally friendly operation. With its holistic
and versatile design, ConsysActive supports a wide range of
applications, from AVL ThermalLab™ to batteries, fuel cells,
e-motors, and e-axles, advancing both testing reliability and
sustainability.
dentifying where energy is used effectively and where
losses occur is crucial for developing modern BEVs. Effi-
ciency has become the key to range, cost, and competi-
tiveness. To master this challenge, AVL applies energy flow
testing using the AVL Vehicle Powertrain TS™ platform,
specifically designed for the development and validation of
electric and hybrid powertrains.
The energy flow testbed uses hub-mounted dynamome-
ters, direct torque measurement, and synchronized sensors
to provide a comprehensive overview of energy consump-
tion – from the wall to the wheel – including non-drive
consumers, e.g., HVAC systems, which are often excluded
from legislative cycles.
Combined with the AVL toolchain, the method delivers
reproducible and highly transparent results. With this front-
loading approach, efficiency losses can be identified much
earlier than in conventional prototype testing. OEMs gain
greater flexibility for design changes, more accurate range
optimization, and ultimately a faster time to market.
AVL E-STORAGE BTE™
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