The test bench set-up with two load machines allows the testing of drives in in-line and transverse configuration. A synchronous machine is used as the drive machine, which can replicate the system behavior of both an internal combustion engine or a traction electric motor. In addition, pure electric and hybrid powertrains including electric machines and power electronics can be investigated on the test bench.

In the context of the research cooperation Vehicle 5.0, the focus of the investigations is on drives optimized for real driving and software-based lightweight design. Testing on the test bench is of key importance for the validation of the models developed at IMS regarding efficiency and transmission loss behaviour as well as fatigue. For the methodical investigations in the context of real driving, a conditioning system also enables the oil temperature in the transmission to be regulated between – 10 °C and + 150 °C, thus enabling the temperature dependence of various parameters to be investigated in a targeted manner. The software-based methods are validated and optimized by means of a large-scale analysis and evaluation of operating data.

In addition, the test bench is suitable for the development of new operation strategy and transmission control functions of novel electrified drive concepts. In the context of electrification, new challenges and potentials arise in the development of operating strategies, especially for multi-speed dedicated hybrid drives, which can be further investigated and optimized with the CONNECT with regard to overall efficiency. Through the functional integration of electrical machines in electrified drives, these can provide transmission functions such as speed synchronization during gear changes. On the CONNECT, model-based developed software functions for the drive system control (or transmission control) of electrified multi-speed drives are thus tested and applied.

  • Measurement, modelling and identification of power losses in conventional and electrified vehicle transmissions (more information )
  • Validation of simulation models in the context of software-based lightweight design and drives optimized for real driving
  • Development and testing of electrified multi-speed powertrain systems with focus on the operating strategy and transmission control (e. g. Speed4E and DE4LoRa )
  • Test bench networking with Driveception for real-time distributed powertrain investigations (Driveception )
Configuration: Front-Transvers Drives, Front-In-Line Drives, Conventional Transmissions (MT, AT, DCT), Hybrid and Electric Drives
Traction Machine: Possible application for transversely and in-line installed drive motors
Rated Torque 500 Nm up to 4.500 rpm
Max. Speed 10.000 rpm
Load Machine: Compact design in transverse direction
Rated Torque 2.000 Nm up to 750 rpm
Max. Speed 3.000 rpm
Conditioning system: Oil Temperature Control -10 °C to +150 °C
Precise Control ≤ ±3 °C
Oil Flow Measurement
Battery Simulator: Emulation of battery for validation and test of pure electric drives
Max. output DC power 150 kW
Max. output DC voltage 800 V
Max. output DC current ±600 A
System software: Automation System PUMA OPEN 2
Control EMCON 6
Torque Sensors Accuracy Class ≤ 0,03
Input and Output shafts
Electric Power Measurement Accuracy ±0.1 % FS (voltage and current)
Power from the battery simulator
Sensor for Oil Temperature -20 °C to +300 °C
Class A according to EN 60751
I/O Connections Analog/Digital, Input/Output, CAN-connection