SIMULATION SOLUTIONS

TEST SYSTEM SOLUTIONS Electrification

TESTINGBattery EQUIPMENT Test Systems AVL Dynamometers and Actuators DynamometersE-Motor Test Systems and Actuators Electronics VehicleTest Systems Testbeds APPROACH DYNAMOMETERS AND ACTUATORS TASK

TestComponent Cell Mechanics The pressure to shorten development time and increase the com- Different test procedures and different engines require different andTest ControlSystems Rooms plexity of testing is increasing, as is the demand on test cells and dy- dynamometers. Engine testing with the original vehicle exhaust MediaMBD on Conditioning the virtual namometers. Dynamometers are the main element in a test cell. They system requires space where the dynamometer is normally mounted. testbed are the components exposed to the hardest working conditions. Consumption MeasurementEngine Test Systems A dynamic dynamometer is needed to run dynamic test cycles. The range of performance of modern engines demands dynamom- The development of intelligent powertrain components through to InjectionEnd of Line Testing Test Systems eters that are of the highest quality technologically, while also highly hybrid systems puts a load on all components, which is comparable Combustion reliable and equipped with precise measurement devices. AVL dyna- to the road test. Therefore, the inertia of the dynamometer should be MeasurementReal Life Test Systems mometers meet these requirements in an optimal way. equal to the inertia of the vehicle’s . EmissionDriveline AnalysisTest Systems and Measurement Combustion engines with high power are also calibrated and tested in Fuel and Lube InTest Vehicle Systems BENEFITS AT A GLANCE low power ranges. Therefore, the requirements for measuring Measurement systems and their accuracy increase. Emission Test Systems and Certification • Dynamometers are available for different applications • Test cell design results in a long life span and low maintenance Torque peaks should not influence any technical values of the torque- Vehicle Test Systems • Fast torque response is provided by rotorflux vector control measuring system. Measuring units can be changed, but the dyna- Racing Test Systems of the stator current mometer must run with low maintenance during its whole lifetime. • Low mass moment of inertia allows a high-speed gradient In case of disruption, the fast delivery of spare parts and well trained • IGBT converters with random pulse pattern reduce engineers must be available to support the customer. the electrical noise in the machine • Recuperation of energy especially in endurance tests It is also important that it is possible to upgrade dynamometers. TESTING EQUIPMENT saves costs and energy • Compact and maintenance-friendly design SIMULATION TOOLS

TESTING TOOLS

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/ 98 DIFFERENT TEST PROCEDURES AND ENGINES REQUIRE DIFFERENT DYNAMOMETERS AND FLEXIBLE ACTUATORS.

DYNAMOMETERS AND ACTUATORS

Engine test cells the inertia of a vehicle wheel AVL test systems AVL offers dynamometers for fulfi l the requirements of real For research and development different engines and test pro- test conditions. Power train test in the vehicle industry, AVL cedures ranging from eddy cur- cells are available for gearboxes, offers tailored solutions in test, rent dynamometers, asynchro- passenger cars with one or more control and measuring technol- nous and synchronous motors driven axles and for Formula 1 ogy. Delivered dynamometers to hydraulic dynamometers for vehicles. can be upgraded with new testing even the largest cross- control systems to satisfy future head engines. High measuring Actuators demands. accuracy and dynamic control Most of AVL’s test cells are are a must for AVL. equipped with the AVL throttle actuator THA. For Powertrain test cells and powertrain test cells, AVL Road to rig reduces develop- offers solutions for gear shift ment time. Dynamometers with and clutch actuation.

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TEST SYSTEM SOLUTIONS LOAD UNIT FOR ENGINE TEST CELLS Electrifi cation

TESTINGBattery EQUIPMENT Test Systems AVL DynoPerform DynamometersE-Motor Test Systems and Actuators Eddy current dynamometers in the AVL DynoPerform series are Power Electronics equipped with drum rotors. An adjustment of the air gap is not nec- VehicleTest Systems Testbeds Using the power unit LSE 410 for eddy current essary. A DC current fl ows through the excitation coil. This creates a dynamometers, very quick load changes are achieved due TestComponent Cell Mechanics variable magnetic fi eld that is dependent on the excitation current. to the modern IGBT technology with PWM control andTest ControlSystems Rooms The magnetic fi eld of the rotating rotor creates eddy currents at the MediaMBD on Conditioning the virtual surface of the cooling chambers. This converts the mechanical energy testbed of the engine into thermal energy. The energy is absorbed by the Consumption MeasurementEngine Test Systems cooling water which can be retroactively cooled via a cooling tower, BENEFITS AT A GLANCE as it is the case for the cooling water for the combustion engine. • Excellent full-range torque and speed control stability InjectionEnd of Line Testing Test Systems • No axial forces on the shaft bearings due to drum rotor design Combustion TORQUE MEASUREMENT • No air gap adjustment required MeasurementReal Life Test Systems The eddy current dynamometer is a cradled dyno. The reaction force • Very fast loading and unloading thanks to an IGBT full bridge EmissionDriveline AnalysisTest Systems of the brake torque is measured with a strain gauge-based load cell. power unit with a 4-quadrant PWM controller (substantially faster and Measurement The measuring accuracy is infl uenced by the linearity of the load cell than a thyristor bridge power unit) Fuel and Lube InTest Vehicle Systems and the hysteresis of the dyno. The torque measuring system is cali- • High permissible weights Measurement brated by load beams and dead weights. The measuring error of the Emission Test Systems and Certifi cation load cell can be compensated by the measuring amplifi er.

Vehicle Test Systems APPLICATION Racing Test Systems Cost-effective dynamometer for tests in R&D, quality control and endurance • Steady-state and transient applications • R&D for engines and components • Tests for fuel and lubrication oil TESTING EQUIPMENT

SIMULATION TOOLS

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/ 100 LOAD UNIT FOR ENGINE TEST CELLS AVL DynoDur Compact

AVL DynoDur Compact™ is optimized to the requirements of basic BENEFITS AT A GLANCE R&D, durability and end-of-line engine test cell applications. The • Fast return on investment system is fully regenerative and fulfi ls stringent EU EMC norms EN thanks to highly effi cient 61800-3 category C3 for operation in industrial mains environment energy recovery and as an optional category C2 for operation in residential mains • Fulfi ls stringent EMC EU environments. The drive cabinet enclosure is equipped with mains norms EN 61800-3 category switch, choke and fi lter as well as a 4Q IGBT power unit. It is, how- C3, category C2 available as ever, very compact and its mains requirements are less than many an option competitive systems. • Low installation costs through compact cabinet CHARACTERISTICS dimensions and optimized Energy is recovered on the mains with high effi ciency and installation mains requirements costs fully optimized. High reliability and, therefore, a high number • High reliability due to robust of yearly operating hours are guaranteed by using a combination of motors an induction motor approved for its robustness in engine testing fi eld • Best-in-class torque measure- together with an industry-based power drive system. ment accuracy and tempera- ture stability APPLICATION The AVL DynoDur Compact™ motors are designed to minimize temperature drift on the -end-side which is equipped for the mounting of a HBM torque fl ange. This leads to best-in-class torque measurement accuracy and temperature stability. By using the AVL patent-pending calibration system, the calibration check can be done with higher accuracy than when using common calibration levers available on the market. The AVL DynoDur Compact™ was developed based on precise requirements and is the perfect cost- optimized solution.

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TEST SYSTEM SOLUTIONS LOAD SYSTEM FOR ENGINE TESTING Electrification

TESTINGBattery EQUIPMENT Test Systems AVL DynoFORCE™ DynamometersE-Motor Test Systems and Actuators The AVL DynoFORCE™ load system consists of a foot-mounted APPLICATION Power Electronics asynchronous AC-induction dynamometer combined with a The DynoFORCE™ series, de- VehicleTest Systems Testbeds 4Q­-­frequency converter cabinet. Together with accessories, it is signed for stationary, transient TestComponent Cell Mechanics a unique solution from a single source for professional testing of and dynamic test runs, can be andTest ControlSystems Rooms transient and dynamic engine applications. The series combines used for various applications, MediaMBD on Conditioning the virtual well-established components with innovative solutions and offers such as vehicle simulation and testbed an optimized balance between TCO and performance. exhaust emission measuring Consumption MeasurementEngine Test Systems of passenger car and truck PRINCIPLE engines. In addition, other InjectionEnd of Line Testing Test Systems Thanks to the high power coverage of each dynamometer, a broad applications such as component Combustion engine portfolio can be handled with just twelve performance class- testing and friction tests are MeasurementReal Life Test Systems es. This ensures highest flexibility with less testbed variants. With its possible. EmissionDriveline AnalysisTest Systems significantly improved torque/inertia ratio, the system is ready for and Measurement testing today’s and future combustion and hybrid engine genera- BENEFITS AT A GLANCE Fuel and Lube InTest Vehicle Systems tions. To achieve real vehicle load transitions, the frequency converter • Efficient testbed usage thanks Measurement cabinet has a fast torque rise time and a high-speed interface to the to a flexible load system solu- Emission Test Systems and Certification controller. High-precision torque and speed measuring instruments tion for transient and dynamic ensure highest repeatability of load conditions and therefore a fast testing tasks. Vehicle Test Systems progress in engine development. Finally, designed for 24/7 opera- • Easy and subsequent system Racing Test Systems tion, best testbed efficiency is guaranteed. upgradeability ensures future­proof solution ahead of challenges. • Optimized Total Cost of Ownership is achieved by TESTING EQUIPMENT improved maintainability and reduction of operation The new dynamometer series cost. SIMULATION TOOLS combines highest robustness and extraordinary dynamics. This provides a very wide The new converter cabinet combines application range and gives latest industrial quality standards TESTING TOOLS the testbed highest flexibility with high performance in order to in various applications. make vehicle simulation reality.

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/ 102 LOAD UNIT FOR ENGINE TEST CELLS AVL DynoExact BENEFITS AT A GLANCE The outstanding measuring accuracy and control dynamics offer • Very high torque accuracy engineers a universal tool for research and development related with hydrostatic bearings to engines and powertrain systems. More than 1,400 systems have option already been installed. The dynamometer was developed by AVL • Option of torque calibration under real test cell conditions. Existing dynos can be upgraded with check during operation new control systems. • Option to recalibrate the dyno down to half of the CHARACTERISTICS dynamometer­ nominal torque It is possible to choose between two different types of cradle bear- to increase the torque mea- ings. The first type uses ball bearings as used in eddy current dyna- surement accuracy for small mometers, and the second type uses friction- and maintenance-free engines hydrostatic bearings. The bending beam used allows more movement • Accurate high dynamic than a load cell in the cradle bearings which increases the life span of torque control the bearings. All cradle parts are covered for safety reasons. • Option of precise vehicle Highly precise, pendulum-mounted, simulation in the test cell The built-in fast torque calculator is optimized with the highly robust AC drive system with a state-of- • Robust industrial design for the-art 4Q-IGBT converter for speed and accurate actual torque signal. Therefore, a fast and accurate torque torque-controlled operation. A real-time operation under extreme signal is created for highly dynamic control loops. torque calculator also provides the shaft ambient and environmental torque of the machine in addition to the electric torque (air-gap torque). conditions • Easy installation and commis- sioning due to precommis- APPLICATION sioned components exam- • R&D, quality and endurance ined in a shop test testing for engine and components • Precise vehicle and driver simulation as well as drive- ability optimization in an engine test cell • Dynamic engine test for racing

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TEST SYSTEM SOLUTIONS LOAD UNIT FOR ENGINE TEST CELLS Electrification

TESTINGBattery EQUIPMENT Test Systems AVL DynoSpirit DynamometersE-Motor Test Systems and Actuators New requirements for engine testing demand new types of dyna- Power Electronics mometers. Standard dynos cannot be used to test an inline engine VehicleTest Systems Testbeds with the original vehicle exhaust system on an engine testbed TestComponent Cell Mechanics because there is no space for it. The AVL DynoSpirit hangs in a frame andTest ControlSystems Rooms and the exhaust system can be installed in the available space below. MediaMBD on Conditioning the virtual The motors used for AVL DynoSpirit have a proven, robust design testbed that has already been used in many applications. Consumption MeasurementEngine Test Systems TORQUE MEASUREMENT InjectionEnd of Line Testing Test Systems The low inertia of the dynamometer allows a stiff driveshaft Combustion connection to the combustion engine. The stiff connection provides AVL dynamic control package BENEFITS AT A GLANCE MeasurementReal Life Test Systems the possibility of fast torque measurement and control. The AVL (KIWI, AVL EMCON™, AVL • Very high speed gradients EmissionDriveline AnalysisTest Systems permanent magnet motors have high torque linearity and high ISAC™), the AVL DynoSpirit thanks to an ultra low rotor and Measurement accuracy in the open torque control loop. In combination with the offers the highest level of dy- inertia Fuel and Lube InTest Vehicle Systems namics and accuracy for torque • Particularly well adapted for Measurement control. applications where space Emission Test Systems and Certification is critical due to very small APPLICATION motor dimensions and weight Vehicle Test Systems Highly dynamic, compact • R&D, quality and endurance • Top dynamics and accurate AC drive system for testing for engine and com- torque control thanks to the Racing Test Systems testing combustion engines consisting of ponents very high motor torque linearity state-of-the-art permanent • Precise simulation of vehicle • Higher torque measurement magnet motor and IGBT frequency converter for load on an engine test cell accuracy than with a 4Q operation with a • Calibration of engine man- foot-mounted asynchronous digital real-time interface. TESTING EQUIPMENT Enables, together with agement systems motor thanks to the lower a portal frame, testing • The dyno is designed for temperature influence from of the original exhaust system. extreme ambient conditions the rotor SIMULATION TOOLS • Robust and compact design for operation under extreme TESTING TOOLS ambient and environmental conditions

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/ 104 LOAD UNIT FOR POWERTRAIN TEST CELLS AVL DynoTrain

BENEFITS AT A GLANCE • Large choice of machines with a suitable speed and torque range selection • Flexible and modular system of motors and inverters, with common intermediate circuit for multiple dynamometer configuration • Robust and service-friendly design

The AVL DynoTrain series is developed especially for use at gearbox and driveline test stands. All parts of the complete AVL DynoTrain family fit into different test applications. This results in a flexible system for different applications.

CHARACTERISTICS Inline torque meters are used for torque measurement. To extend the measuring range, the inline torque meter can be adjusted to the required torque range. Together with the AVL DynoPrime, the energy runs in a loop and only the losses of the system are taken out of the grid.

APPLICATION • R&D, quality and endurance tests for gearboxes and drivelines • Development of drivelines for vehicles with one or more Modular asynchronous motor and converter system, designed for application at transmission and driven axles powertrain test cells. The 4Q-IGBT converter is equipped with a digital real-time Interface. • NVH measuring

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TEST SYSTEM SOLUTIONS LOAD UNIT FOR POWERTRAIN TEST CELLS Electrification

TESTINGBattery EQUIPMENT Test Systems AVL DynoWheel DynamometersE-Motor Test Systems and Actuators The AVL DynoWheel series is designed for use at gearbox test Power Electronics stands. Two different characteristics are provided by this dynamometer: VehicleTest Systems Testbeds low mass inertia and very high torque at low speed. Together with TestComponent Cell Mechanics AVL DynoPrime, the energy runs in a loop and only the losses of the andTest ControlSystems Rooms test system have to be supplied by the grid. MediaMBD on Conditioning the virtual testbed CHARACTERISTICS Consumption MeasurementEngine Test Systems The inertia of the dynamometer is equal to the mass inertia of a vehicle wheel. It is possible to simulate the same drivability as on the InjectionEnd of Line Testing Test Systems road as well as wheel slip. Not only the vehicle acceleration but also Combustion the driveline vibration of the vehicle is similar to reality. Fast control MeasurementReal Life Test Systems loops make it possible to optimize the driveline for one or two driven APPLICATION EmissionDriveline AnalysisTest Systems axles. The AVL DynoWheel drives are powertrain testing systems with • Application wherever the simulation of the dynamic vehicle values and Measurement features specially developed to provide the best results when the is important Fuel and Lube InTest Vehicle Systems highest accuracy and control dynamics are required. • The AVL DynoWheel is directly coupled to the axle shafts Measurement • The tire stiffness and slip is controlled by the AVL control systems Emission Test Systems and Certification BENEFITS AT A GLANCE Vehicle Test Systems • Machines with very low inertia adapted to the real vehicle wheel Racing Test Systems • Optimized for reproduction of realistic wheel loads and torsional behavior • Accurate test execution and excellent repeatability due to high torque control linearity • Flexible and modular system for motors and inverters with com- TESTING EQUIPMENT mon intermediate circuit for multiple dynamometer configuration • Service-friendly power unit SIMULATION TOOLS

TESTING TOOLS

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/ 106 LOAD UNIT FOR DRIVETRAIN TEST CELLS AVL DynoPrime

The AVL DynoPrime series is designed to replace a combustion AVL DynoWheel dynamome- engine on gearbox and powertrain test stands. ters. The real vehicle behavior can be simulated in a system REQUIREMENTS with one AVL DynoPrime and The mass inertia of the dynamometer has to be equal to the inertia two or four AVL DynoWheels. of the combustion engine. Torque pulses of a combustion engine The dynamometers are water must be simulated. The center height must be very low. If the dyno is jacket-cooled and supplement- mounted to the bell housing of a front wheel drive vehicle, enough ed by a closed air-cooling loop space must be provided to mount the axle shafts. for the rotor. This makes noise measurements on a gearbox CHARACTERISTICS test stand more efficient. • Very low inertia BENEFITS AT A GLANCE • Low center height APPLICATION • Inertia similar to a combus- • High overload capability • Development and optimiza- tion engine tion of the driveline before • High nominal torque (larger With its interfaces and dynamics, the AVL drive converter of the the vehicle engine is available than ICE), plus additional AVL DynoPrime corresponds to the converters of AVL DynoTrain and • R&D for gearboxes, drivelines overload torque capability and vehicle parts that are for simulation of speed influenced by the characteris- oscillations tics of the combustion engine • High flexibility in the parame- • Wear tests under dynamic terization of various charac- conditions teristics of engines • Noise measuring • Cost savings due to simpler setup of transmission and driveline testbeds • Simple retrofitting into AVL DynoPrime is a highly dynamic existing test cells is ensured PMM drive system for the simulation of by using the throttle as a the rotational behavior of the of combustion engines. The system is demand value. Existing drive characterized by high nominal cycles can be used without and a high overload capacity with the smallest moment of inertia. modification

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