Test benches: testing at test benches

ATESTEO test benches for drivetrains and powertrains are designed to test transmissions as a subassembly, as part of the drivetrain, or as part of the entire vehicle. ATESTEO conducts functional and endurance tests of transmissions and drivetrains on more than 150 test benches adapted to customer specifications. At the test benches, the drive is supplied by combustion engines or electric motors; the latter permits simulating battery systems. All our test benches are set up for tests on passenger cars or commercial vehicles. The testing laboratory is accredited in accordance with DIN EN ISO/IEC17025:2005 by the German Accreditation Body (Deutsche Akkreditierungsstelle, DAkkS). This also officially certifies ATESTEO’s technical competence in drivetrain and transmission testing. Our service range for drivetrain test benches is continuously adapted to the new demands of the market and takes into account the growing demand for testing electric and hybrid drives. Your components can thus be tested at our test benches during very early project phases. This supports or objectifies your decisions for specific technologies at the right point in time. The drivetrain test benches are fitted out with equipment ranging from a single electric motor to five electric motors as well as set-ups for special applications.

Our test bench equipment:

  • Operations 24 hours a day, 365 days a year
  • Automation and control system developed in house
  • System for the early detection of damage
  • Dynamic simulation of rolling resistance
  • Block programme tests
  • Retracing of vehicle measurement data in real time
  • Entry of data on a road or a stretch of road
  • Rest bus simulation
  • High-voltage DC current supply
  • Electric load motor
  • Measurement of temperature, volume flow, and pressure
  • Axle coupling
  • Axle blocking mechanism
  • High-frequency measurement of DC voltage, DC current, AC phase voltage, and AC phase currents
  • Measurement of rotational speed, torque, and rotor angle
  • Speed control
  • Coolant conditioning
  • Vibration-free fixture (clamping device)
  • Temperature test chamber

We offer the following range of tests at our test benches:

  • Transmissions and drivetrains
  • FWD, RWD, AWD, transaxle systems
  • M/T, A/T, AMT, DCT, CVT
  • PTU, transfer drive, front/rear axle differential
  • Transmissions with auxiliary units
  • Hybrid systems • Hot/cold endurance tests
  • Efficiency measurements
  • Noise, vibration, harshness (NVH) analysis
  • Long-term service life and shifting quality of synchronisation, shifting quality analysis
  • Deformation analysis

Combustion engine test benches

Time is money, and it’s important to save both when developing drivetrains. Testing early so that the transmission can be optimised in its fuel consumption and carbon dioxide (CO2) emissions is a key factor when engineering efficient technologies. The drivetrain test benches at ATESTEO do not require either a complete drivetrain or a finished prototype. You can test the properties and performance of your technologies or components at our drivetrain test benches during the development phase.

Testing the entire system at drivetrain test benches

To test the entire system, even without a prototype, ATESTEO makes available modern, multifunctional drivetrain test benches on which various powertrain configurations can be tested with only one set-up at the test bench. Your manual, automatic, and double-clutch transmissions, along with continuously variable transmissions and hybrid drivetrain technologies, can also be tested. The drivetrain is tested under realistic conditions as driven by combustion engines. You can decide whether the tests are performed in a quasi-stationary or dynamic fashion.

Modelling the vehicle at drivetrain test benches

The ability to install an entire vehicle makes it possible for automatic transmissions to be calibrated for the testing of safety-related functions already on the drivetrain test bench before engaging in road tests. It is possible to replicate on the test bench original measurement data from the vehicle, to model geographic data from your test tracks, or to perform a block profile. Hybrid and electric vehicle applications are supplied with direct current during operation.

Combustion engine options for drivetrain test benches

Combustion engine options for drivetrain test benches

  • CE electric engine test bench
  • CE two-drive electric engine test bench
  • CE three-drive electric engine test bench
  • CE four-drive electric engine test bench

Electric motor test benches

When combustion engines are developed at the same time as the transmission owing to ever shorter development timeframes, our test benches assist you to test the transmission during an early stage, even without a completed engine. This delivers you valuable performance data and reduces the costs of prototypes.

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Hybrid drive powertrain test benches

For testing hybrid drives, ATESTEO offers state-of-the-art test benches that simulate the operation of the drivetrain in a realistic manner.

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Testing at HiL test benches with regard to NVH and service life

Requirements for passenger vehicles are constantly subject to change. Apart from service life, comfort is of vital importance. Noise, vibration, and harshness (NVH) behaviour is especially crucial in this regard. Corresponding optimisation of acoustic and vibrational performance leads to less vibrational strain on the driver. The drivetrain represents a significant source of vibrations and noise.

The importance of validation has increased as new components are tested and approved. Through the development of new vehicle drivetrains and with an increasing proportion of mechatronic systems, the requirements for the individual components are becoming increasingly complex and the tests more comprehensive.

Testing vehicle components under realistic operating conditions at the HiL test bench

With the rapid increase in the number of electronic components and with increasing functionality, especially with regard to drivetrain electronics, along with constantly shortening development times, the test processes at HiL test benches are an effective platform for improving testing possibilities. The HiL test bench enables transferring the system behaviour of the drivetrain onto the components. The HiL test bench includes a test bench model coupled to a vehicle simulation model. The simulated interactions are transferred from the highly dynamic electric motor to the component being tested.

Using the HiL test bench to make sure the system works as planned

The Hardware-in-the-Loop (HiL) process in the HiL test bench uses an embedded system and a simulator to simulate the real (physical) environment in which the system will later operate. HiL testing enables individual components of the drivetrain to be tested on the HiL test bench during a very early stage in the development process, using specifications related to later operation, without necessarily requiring other drivetrain components. We are thus able to make sure, at a relatively early stage, that your system works as planned, which supports your development process.

 

Our services at the HiL test bench at a glance:

  • Verification and validation of complex systems and components
  • Analysis of NVH behaviour
  • Analysis of dynamic behaviour
  • Investigations with respect to service life

Acoustic test benches for the drivetrain

The shorter the development times, the more important parallel testing of the elements of your drivetrain becomes. You can achieve a significant time saving by developing and optimising vehicle part systems at special acoustic test benches.

Tests at acoustic test benches for drive types MT, AT, DCT, HEV, PHEV, BEV

Formerly, tuning these systems to specific needs could be begun only once vehicle prototypes were available. At ATESTEO acoustic test benches, substantial optimisation of vibrations of the entire drivetrain can start much earlier. This enables you to reduce costs considerably by reducing the number of your vehicle prototypes. It is possible to test the drive types MT (Manual Transmission), AT (Automatic Transmission), DCT (Dual Clutch Transmission), HEV (Hybrid Electric Vehicle), PHEV (Plug-in Hybrid Electric Vehicle), and BEV (Battery Electric Vehicle) at our acoustic test benches.

Analyses of NVH phenomena such as transmission rattling and whining

To determine the source of transmission rattling, the drive engine is able to simulate the torsional oscillation of a combustion motor. With extensive expertise and specially adapted measuring and testing technology, we support you to develop torsional vibration dampers such as friction washer dampers, dual-mass flywheels, and converter clutches with torsional vibration dampers for passenger vehicle drivetrains.

Key figures of our acoustic test benches:

  • Measurement of all types of drivetrains
  • Suitable for all electrified types of drivetrains
  • Simulations of combustion engine, drivetrain and components and battery
  • Certified in accordance with ISO 3745 class 1
  • Frequency range 150 – 16,000 Hz • Interfering noise < 35 dB(A)
  • Parameters at the drive system: nmax = 20,000 rpm, Tmax = 600 Nm, JRot = 0.064 kg/m2
  • Parameters at the output drive: nmax = 8,000 rpm, Tmax = 4,000 Nm

Transmission rattle test bench (Transmission acoustic test bench ATE anechoic test chamber)

With its transmission noise test bench, ATESTEO offers you a possibility, certified in accordance with ISO 3745 class 1, to investigate a great variety of transmission noises, separate from the remaining drivetrain. With transmission whine, which is caused by the teeth meshing, up 6000 rpm and 490 Nm can be measured on the primary shaft. To measure gear rattle that is generated by the loose parts stochastically knocking against one another, the drive motor is able to simulate the torsional oscillation of a combustion engine.

With a high level of expertise and specially-adapted measurement and testing technology, we also support you in developing torsional vibration dampers such as friction washer dampers, dual-mass flywheels, and converter clutches with torsional vibrations damper for a passenger car drivetrain.

Key figures of our transmission noise test bench:

  • Certified in accordance with ISO 3745 Class 1
  • Cut-off frequency = 250 Hz
  • Disturbing noise level inside test cell = 45 dB(A)
  • Disturbing noise level outside test cell = 80 dB(A)

Test benches for rail vehicles, commercial vehicles, and off-road applications

Commercial vehicles are an important part of modern transport systems, presenting unique challenges for the drive technology, vehicle, engine, and transmission. With a committed team of commercial vehicle specialists and extensive technical expertise, we are your strong partner when it comes to supporting special tests for rail vehicles, commercial vehicles, and off-road applications.

ATESTEO test bench applications beyond passenger cars:

  • Rail vehicles
  • Commercial vehicles
  • Off-road applications