GKN Automotive, the drive systems specialist, has created a ‘real-time’ test rig capable of handling the unique requirements of EVs.
The rig, installed at GKN Automotive’s Offenbach facility, can handle the extreme dynamics and higher torque of electrified powertrains, which make conventional load test rigs unsuitable for driveline parts of the latest generation, such as side shafts.
It can test specific load data provided by customers, from small electric city cars to SUVs and is able to dynamically control speed and torque to replicate wheelspin and other complex driving conditions.
The firm’s engineering expertise is crucial to correctly setting up and executing tests on the new rig.
Data must be selected and validated by the team to establish parameters for the test, and the system must be carefully calibrated during set up to accurately replicate precise load dynamics.
GKN Automotive is already providing eDrive systems to more than two million electrified vehicles across the globe, with core driveline components selected for use in powertrain systems by several of the world’s leading EV manufacturers.
Mario Syhre, Director Product Technology at GKN Automotive, said, “Electric vehicles place different load dynamics on our driveline components and this new rig allows us to accurately reproduce those to achieve an unprecedented level of testing.
“Components need to be much stronger to cope with the higher torque and the extra weight of EVs, without increasing significantly in size or weight, and remain as cost-effective as possible.
“The new rig allows us to accurately replicate the loads on our components, from small electric city cars to the most powerful SUVs, and deliver the lightest, most efficient solution.”