E-Axle and E-Drive Test Bench

Product Description

JKT E-Axle and E-Drive test benches are fully customized and engineered to satisfy the full-spectrum testing demands of all types of electric axles and integrated electric drive assemblies ranging from passenger car compact e-drives to heavy-duty commercial vehicle e-axles. The system is capable of highly accurate, high-fidelity simulation of real-world road driving conditions as well as diverse complex actual operating load cycles of the unit under test (UUT). It delivers comprehensive all-round testing capacity covering steady-state & dynamic performance mapping, long-term durability cycling, NVH noise-vibration-harshness measurement, transmission efficiency profiling, differential mechanical characteristic testing, vehicle control strategy calibration and matching, alongside reliability and endurance validation under extreme high/low temperature, humidity and alternating thermal environments.

High-precision sensors and high-speed data acquisition modules built into the bench enable precise real-time measurement of core working parameters including output torque, rotational speed, power transmission efficiency and component temperature rise throughout the whole test cycle. Engineers can thereby proactively detect latent structural design defects, power performance bottlenecks and assembly matching abnormalities at the early R&D stage. This effectively eliminates potential on-road safety hazards, cuts costly post-production rework and economic losses, and drastically upgrades overall testing precision and data repeatability for new energy powertrain development.

The JKT transmission and reducer test bench integrates three core high-performance subsystems: a rigid, low-vibration mechanical frame with ultra-high positioning accuracy and long-term operational reliability, a high-dynamic closed-loop control system featuring ultra-fast response speed and outstanding operating stability under variable load shocks, and a full-featured powerful software suite with customizable test scripts, automatic data logging, visualized curve analysis and standardized test report generation functions.

To accommodate diversified customer development demands, JKT supplies both transverse and longitudinal layout transmission test bench solutions, which boast wide compatibility and can be deployed for testing powertrain components of passenger cars, light commercial vehicles, heavy-duty mining trucks and off-road engineering machinery alike. Our transverse transmission test bench adopts an innovative structural layout with an ultra-short wheel center distance, which perfectly matches the installation space constraints of highly integrated compact transmissions widely adopted in battery electric vehicles and hybrid electric vehicles, realizing seamless clamping and testing of miniaturized e-drive units. Taking the distinct structural differences between coaxial reducers and conventional offset reducers into full consideration, JKT has independently developed a universal multi-functional test bench platform that supports simultaneous testing of both coaxial reducers and traditional gear reducers, greatly expanding the equipment’s application coverage and lowering customers’ investment in multiple separate test rigs.

1.1 Technical Conditions

（1）Ambient temperature：5℃～40℃

（2）0Relative humidity: 20%....90%，not condensing

（3）Power supply 

（220±10%）VAC /50Hz，50kVA

（380±10%）VAC /50Hz，400kVA，Grounding resistance≯3Ω

（4）The laboratory shall have good ventilation and exhaust function, and the ventilation and exhaust system shall be provided by Party A

（5）Compressed air pressure: (0.5~0.6) Mpa, Party A shall provide compressed air after drying：（0.5～0.6）Mpa

（6）The inverter should be installed on independent room, and there is air conditioner.

1.2 Model selection of Drive and load motor

Wheel-side loading motors are used to simulate wheel-end loads, and dynamometers can be selected according to test requirements. If low moment of inertia dynamometers are needed, permanent magnet synchronous motors or customized high-dynamic asynchronous motors can also be adopted.

Load Motor Parameters for E-Axle and E-Drive Test Bench:

Note: Environmental chambers are optional for E-Axle and E-Drive test benches.

JKT can provide customized products according to customer requirements.

1.3 Main Technical Parameters

(1) Torque measurement control accuracy：±0.05%FS

(2) Speed sensor pulse resolution：1024/600ppr

(3) Torque control accuracy：±(0.5~1)%FS

(4) Speed control accuracy：±(0.01~0.05)%FS

(5) The max vibration value of dynamometer（RSM）：≤2mm/s（no load）

(6) The bearing support temperature rise：≤35℃

(7) The max vibration value of the bearing support（RSM）：≤2mm/s（no load）

(8) DAQ sampling rate：1kHz

(9) Current measurement channel:4/6

(10) Voltage measurement channel:4/6

(11) Measurement accuracy of power analyzer: ±0.05%

(12) Temperature sensor measuring range: -50℃~200℃

(13) Measurement accuracy of temperature sensor: A class

(14) Vibration sensor measuring range: 0~20mm/s

1.4 Typical Application Project for E-Axle and Powertrain

Test benches test electric axle or electric drive of the electric vehicles (EVs).

Main test contents：

(1) Efficiency test

(2) Torque test

(3) Speed test

(4) Differential test

(5) Temperature rise test

(6) Over-load test

(7) Steady-state test

(8) Maximum speed test

(9) Durability with temperature climate test

(10) CLTC/WLTC cycle condition test

(11) User-defined cycle condition test

(12) Controller calibration test

(13) Road load simulation test

(14) Accelerated response test

(15) Torque response test

(16) NVH test (option)

Basic configurations:

Dynamometer & Mechanical System: Two high-dynamic asynchronous motor are selected as the load motors, equipped with a high-speed drive shaft system and precision, reliable mechanical components. Each load unit can be moved along the axis direction for different UUT.

Frequency Converter: Four-quadrant frequency converters are adopted for dynamic or steady-state control of the dynamometer. It enables control of rotational speed, torque, allowing the dynamometer to operate in either motoring or generating mode.

MCU Power Supply: Provides an adjustable low-voltage power supply for the motor controller.

Test Object Cooling System: Supplies cooling medium for the tested E-axle and E-drive. An oil or water-cooling system is available for certain oil-cooled or water-cooled test pieces. Parameters including temperature, pressure and flow rate of the cooling system are fully adjustable. The water-cooling system can also use ethylene glycol as the cooling medium.

Climate Chamber: Provides a simulated operating environment with controllable high/low temperature and humidity for the test objects.

Automated Measurement & Control System: Conducts overall control and condition monitoring of the entire motor test bench.

E-drive(Powertrain) test bench (400kW 4000N.m 3000rpm)

1.5 FAQ

Q 1: What is the main application scenario of your E-Axle and E-Drive Test Bench?

A1：This test bench is specially developed for new energy vehicles, covering battery electric vehicles and hybrid electric vehicles. It is used for full-performance bench testing of integrated electric drive assemblies, electric axles, reducers and drive motors in the early R&D stage of automobiles, to verify the reliability, efficiency and dynamic performance of the E-drive system before vehicle assembly.

Q 2: What core testing items can this equipment complete?

A2：It supports comprehensive test items for electric drive systems, including efficiency mapping test, torque-speed characteristic test, temperature rise & thermal cycle test, durability fatigue test, NVH noise vibration test, coast-down loss test and overload impact test, covering all mainstream verification standards for new energy vehicle drive systems.

Q 3:How can this test bench help auto manufacturers shorten vehicle development cycles?

A3：Our bench realizes full offline simulation testing of E-axle components without whole vehicle matching in the early stage. It can expose design defects of reducers, motors and shell structures in advance, avoid repeated vehicle road test revisions, greatly reduce prototype iteration times, and cut the overall new vehicle R&D cycle by 30%–50%.

Q 4：Does Jingke Test support customized modification of this E-drive test bench according to customer’s test requirements?

A4：Yes. As a professional domestic test equipment manufacturer (Anhui Jingke Test Technology Co., Ltd.), we provide fully customized services. We can adjust the maximum load torque, rotational speed, power level, environmental temperature chamber, dual-motor loading structure and data acquisition system according to customers’ E-axle specifications, test standards and factory site conditions, and deliver one-stop turnkey test solutions.