Validation of design is crucial….
Physical testing of electro-mechanical systems is a key part of the design chain, ensuring the product can carry out the required duty cycle over the product life time without fail.
Infinite System Design, through the technical partnership with Drive System Design, has extensive experience in test and development with flexible capabilities in both test, post processing and investigation. Development testing capabilities include 8-D methods with a large torque range from 0.05 Nm to 20,000 Nm and versatile data analysis techniques.
Please note the testing facilities are based in the UK.
Test and Development Capabilities:
- 360kW and 300kW (peak) battery simulators
- Durability & efficiency dynos – up to 460kW input power, 5500Nm per axis output torque
- Clutch and brake performance
- Actuator development dynos
- Lubrication development
- Hydraulic testing
- Efficiency development
- NVH & acoustics
- eDrive characterisation & performance
- Universal inverter for eDrive testing
Test Rig Design Capabilities:
Infinite System Design is also able to offer rig design and build services including custom rig design for electric motors, transmission and other mechanical systems including bespoke, HMI (Human Machine Interface) and controller capabilities with a modular approach. An example of which may be to use a dSPACE system to control inverters/motors to run a mechanical system through set duty cycles.
Case Study: Test Rig Design / Implementation
Our technical partners Drive System Design completed the design, build and commissioning of a new powertrain test rig utilising extensive experience across all types of transmissions, drivelines, sub-systems and components. A bespoke rig control system was developed including GUI, hardware and software. The test rig included data acquisition and analysis systems with high-speed data logging and time/frequency domain analysis (Campbell diagrams / power spectral density, coherence).
Case Study: Transmission Efficiency Analysis
Our technical partners Drive System Design carried out physical testing and efficiency analysis on a transmission across a full range of input torques/speeds and operational temperatures. Utilising a three stage approach, initially the rotating components were reverse engineered then a transmission model was developed utilising MASTA and Drive System Design proprietary techniques. Finally, full rig based testing was carried out to validate the model over a temperature range of -20-120 Deg C. The physical testing included spin loss testing, loaded efficiency measurements and hydraulic subsystem testing.
Case Study: Transmission Durability Testing
Our technical partners Drive System Design helped a low volume manufacturer of highly specialist vehicle transmissions to quickly carry out loaded durability test on a 220kW driveline which had the technical challenge of rapid output torque fluctuations. A 3E test rig was reconfigured to match the transmission architecture and then using expert knowledge of the rig control system, the torque was ramped up to full torque in 100ms. The test piece mounting fixtures were designed and manufactured in-house and testing took under three weeks to deliver a 300 hour durability test cycle.