OEMs and suppliers are developing new propulsion system concepts, transitioning from traditional transmission technologies (manual, automatic, dual-clutch) to fully electrified powertrains. Electric drives and high-voltage components are now central to this shift.
To support development and system integration, customers require testing systems that not only evaluate mechanical subsystems but also optimize high-voltage electrical subsystems. These testing solutions ensure that both mechanical and electrical components are seamlessly integrated, enabling efficient and reliable performance in modern powertrain designs.
Performance Testing – Light Duty
This test system uses two or four dynamometers directly mounted at the wheel hub, delivering torques from 3,200 Nm to 7,000 Nm and outputs between 220 kW and 500 kW. For electrified powertrains, a battery emulator of up to 1,000 kW typically replaces the real battery. Advanced vehicle dynamics simulation enables precise execution of driving maneuvers under various road and load conditions, supporting frontloading in development.
Performance Testing – Heavy Duty
Two, four, or more dynamometers provide torques of up to 40,000 Nm for high-performance heavy-duty applications. To meet extreme torque demands, matching transmissions may be required. Electrified systems use a battery emulator with an output of up to 1,000 kW. Powerful simulation tools enable realistic driving scenarios and accurate performance evaluation of complex heavy-duty propulsion systems.
NVH Testing
For NVH testing, two or four dynamometers apply dynamic loads to the propulsion system. To maintain a low acoustic environment, the dynos are placed outside the NVH chamber. This setup allows accurate testing of noise and vibration behavior without external interference. The testbed supports detailed acoustic investigations of powertrain components under realistic conditions.
System and HV Integration
This solution is based on a fully automated propulsion test system with four high-dynamic wheel dynamometers. It includes load units, conditioning devices, and measurement tools for torque, speed, temperature, and more. For HV systems, it is extended with high-power sinks/sources, fast-sampling voltage and current sensors, and mains emulation to support full system validation.
Our modern powertrain test systems are designed to validate all types of propulsion systems, including 2WD, 4WD, and electrified powertrains. They support a wide range of speeds, torques, power classes, and voltage and current levels. The dynamometers simulate real-world driving conditions, road data replication, or time-lapsed testing, providing precise speed and torque control. AVL's optimized hardware and software toolchain significantly accelerates the design and validation process, allowing for early testing in a virtual environment (frontloading).
The AVL PUMA 2™ automation software enhances the system by synchronizing measurements from all devices, ensuring high data quality. This precision, combined with the system’s measurement, control, and simulation capabilities, allows customers to perform real-world driving maneuvers and energy consumption tests without needing a physical vehicle. As a result, propulsion systems can be developed more efficiently, reducing development time and increasing overall project success.
Propulsion system architecture and components have evolved rapidly in recent years, leading to new challenges and opportunities. AVL continues to provide tailored solutions that enable our customers to focus on development with confidence, knowing their measurement results are accurate and reliable."
– Dr. Klaus Pfeiffer, System Line Manager, AVL Deutschland GmbH
AVL powertrain system testing solutions are built on innovative, proven technologies, from dynamometers supporting various power classes to automation software that adapts to a wide range of applications. Our deep application expertise and system integration capabilities drive efficiency for our customers.
We provide the perfect powertrain testing solution tailored to your specific needs, whether it’s for performance optimization, durability testing, or the integration of complex high-voltage components.
The AVL Customer Services organization consists of more than 700 service- and application engineers worldwide, operating from more than 50 locations. Our global footprint is your local benefit.
AVL PUMA 2™ is the global industry standard for testbed automation. It is suitable for electrified testbed types as well as for conventional test environments.
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The device is AVL’s all-in-one solution for RDE/ISC requirements. It ensures precise and reproducible emission measurements under real driving conditions.
Portable on-board soot and PM measurement device.
The SPECTRA converter system is a modular silicon carbide (SiC) converter able to control wheel dynos at unprecedented levels of control accuracy and dynamics thus helping you to test your powertrain with confidence.
Battery tester and emulator for research and development, testing and validation.
The market-leading testbed monitoring and control system for a variety of propulsion systems
AVL’s comprehensive worldwide network of experts allows best customer vicinity, ensuring consistent and connecting testing fields globally. Wherever your R&D challenges take you, we are always close at hand, ready to provide the service you need.
> 70
years of experience
> 5,000
employees worldwide for testing solutions
> 30
countries covered by the global network
> 7,000
testbeds installed worldwide
> 80
turnkey projects