Testing Services

OUTSOURCE THE TESTING, FOCUS ON THE RESULTS

With our test facilities in Graz and Friedrichshafen and our product range, we can offer testing services for complex and varied challenges in powertrain technology and energy systems.

Our Testing Center teams handle all demands from development to series validation – whether for conventional drive systems or your visionary ideas for the future.

Testing often needs to be carried out even though the necessary infrastructure does not exist or existing resources are in use. With our in-house testing systems, we offer an alternative solution. Our experienced staff take care of the required testing, including the associated logistics and data management, with a clear focus and dynamic flexibility. State-of-the-art testing technology enables functional testing using different approaches and methodologies for the entire range of development stages.

We work quickly and economically to develop unconventional solutions for you.
Get in touch and put us to the test!

testing@ksengineers.com

CLASSIC ENGINE TEST BEDS

Highly transient 4-quadrant asynchronous machines with KS FC (29,000 Nm S1)
Inertia compensation for realistic, application-oriented testing
Flexible pallet system for engines up to 4900 kW
Separate exhaust gas disposal with silencers designed to create minimal backpressure
Generously dimensioned areas, incl. for AGN systems
Conditioned test cell (80,000 m³/h)
Seawater cooling for marine engines with seawater pump (pressureless supply/return)
Horiba fuel conditioning system (15-60°C)

R2R COMPLETE VEHICLE INTEGRATION TEST BED

Function- and scenario-based testing

Model-based testing
XIL applications, testing in all development stages
Testing of ADAS functions
Testing for road approval
Compatible with IPG CarMaker
Hot braking
Maximum degree of loading realism on the powertrain using KS test wheel

Testing just as on the road – except that it’s reproducible and reliable

Accredited testing laboratory according to EN ISO/IEC 17025:2017 (ID 0474): Power measurement at the wheel hub according to

ECE/Trans/180/Add. 21 (UN GTR 21): Determination of Electrified Vehicle Power (DEVP), continuous vehicle power and peak vehicle power
SOP 760067 KS power measurement

R2R CV ELECTRIC DRIVE TEST BED, 2 MACHINES

Test bed with 2 machines for CV hybrid drive modules and electric axles

Front transverse or rear longitudinal set-ups incl. combustion engine
2 highly transient 4-quadrant asynchronous machines with KS R2R FC (30,000 Nm, S1)
550 kW each, overload-capable at 770 kW each for 60 s
Wheel machines traversable to max. 4 m specimen size / axle track
Oil & water conditioning, heating + cooling, flow control
Battery simulator, 822 kW (1200 A/5-1000 V)
Tornado automation system
Vehicle and track simulation
6-phase power measurement with Yokogawa Power Analyser
Torque measurement, HBM T12 HP 50 kNm

POWERTRAIN TEST BEDS, 2 MACHINES

2-machine test bed for hybrid-drive modules, electric axles, front transverse set-ups incl. combustion engine (2x 440 kW)
Oil & water conditioning, heating + cooling, flow control
Battery simulator, 360 kW (1000 A/5-1000 V) Overload-capable, 470 kW for 60 s
Vehicle and track simulation
6-phase power measurement with Yokogawa / HBM Power Analyser
Torque measurement, HBM T12 HP 5 kNm

Back-2-Back e-axle test beds (B2B)

8 units for e-axle modules in Back2Back combination:

Linkage for connection of axle modules

Battery simulation:
- Continious power 120 kW
- Continious current: 200 A
- Voltage range: 40 - 800 V
Climate conditioning:
- Temperature- and humidity controlled climate chamber
- -40 to 120°C air temperature
- 0 to 98 % humidity
- Temperature gradient up to 8°C/min
Coolant conditioning:
- Temperature, pressure and flow controlled
- -40 to 120°C coolant temperature
- Temperature gradient up to 10°C/min

R2R POWERTRAIN TEST BED, 2 machines with ICE

For BEV and PHEV applications:
Two asynchronous machines, each with:

Continuous power: 375 kW or 440 kW
Continuous torque: 3200/3500 Nm, brief overload of 6700 Nm
Maximum speed: 3000 rpm
Representation of wheel moments of inertia from 1.3 kgm²

R2R POWERTRAIN TEST BED, 4/5M (AWD)

For BEV and PHEV (AWD) applications:
Four asynchronous machines, each with:

Continuous power: 375 kW or 440 kW
Continuous torque: 3200/3500 Nm, brief overload of 6700 Nm
Maximum speed: 3000 rpm
Representation of wheel moments of inertia from 1.3 kgm²

One synchronous machine as the driving machine:

Continuous power: 420 kW, overload of 750 kW
Continuous torque: 800 Nm, brief overload of 1400 Nm
Maximum speed: 9000 rpm
Moment of inertia, 0.15 kgm²
Rattle-proof, with Matlab/Simulink ICE model (customisable)

Battery simulation:

Continuous power: 960 kW or 1100 kW
Continuous current: 1600 A
Choice of voltage range: 5-600 V, 650-1000 V or 10-1000 V

Electric motor test bed

Speed up to 40.000 rpm
Dyno: synchronous machines from 175 kW to 420 kW
KS R2R frequency converter for highly dynamic applications
AC/DC-box for open-loop and short circuit test
HBM T12 HP torque sensor
Power measurement with 6-phase Yokogawa Power Analyser

R2R POWERTRAIN TEST BED, 3 MACHINES

R2R axle test bed for BEV with and without specimen drive source
One synchronous machine as the driving machine, for example:

One synchronous machine as the driving machine, for example:
Continuous/peak power up to max. 400/500 kW
Continuous/peak torque: up to 545/681 Nm
Maximum speed: up to 20,000 rpm
Moment of inertia from 0.075 kgm²

Two asynchronous machines as output machines, each with:

Continuous power: 440 kW
Continuous torque: 3500 Nm, brief overload of 6200 Nm
Maximum speed: 3500 rpm
Representation of wheel moments of inertia from 1.3 kgm²

Your contact person at our testing center in Friedrichshafen

Florian Kaiser

testing@ksengineers.com

Your contact person at our testing center in Graz

Martin Wipfler

testing@ksengineers.com