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

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
  • Klimatisierung:
    • 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

KS Fit Box

  • 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
  • Climate cell

Flexible testing in the smallest space possible with all the advantages of the R2R test system.

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

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, 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 

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

 

Your contact person at our testing center in Graz

Martin Wipfler

testing@ksengineers.com 

Your contact person at our testing center in Friedrichshafen

Florian Kaiser

testing@ksengineers.com