SIMULATION SOLUTIONS TEST SYSTEM SOLUTIONS Electrification TESTINGBattery EQUIPMENT Test Systems AVL Dynamometers and Actuators DynamometersE-Motor Test Systems and Actuators Power 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 wheel. 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 torque 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 CUSTOMER SERVICES / 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 transmission 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. / 99 SIMULATION SOLUTIONS 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 coupling 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 TESTING TOOLS CUSTOMER SERVICES / 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 motor drive-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. / 101 SIMULATION SOLUTIONS 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