OEMs and suppliers are now developing components for innovative propulsion systems. Unlike the previous focus on ICE, the shift to fully electrified drivetrains introduces new challenges.
Our drive units must adapt to these changes by supporting e-drives, which require smaller, high-power-density solutions capable of higher speeds and greater flexibility. The design of e-motors also introduces a wider range of variants compared to ICEs, demanding more versatility from our testing systems.
Our transmission test systems are engineered to validate a wide range of transmissions, addressing varying types, speeds, and power classes. The main challenge lies in integrating an ICE or e-motor within a compact, close axle arrangement. The AVL drive unit is designed to meet the necessary speed and torque requirements while ensuring compatibility with the available installation space. Our solutions are capable of handling the variability of e-axles in both co-axial and offset configurations, along with the intelligent mechanical connection of e-motors to transmissions.
The optimization of the design and validation process is a key benefit, as our systems allow for early-phase transmission testing, even without a fully developed propulsion unit. This reduces the likelihood of design changes in later development stages. In addition, AVL PUMA 2™ automation software adds significant value to the testing process by synchronizing data from all connected devices. This results in precise measurement and control, enabling faster transmission system development through various test types, such as transient, time-lapse, and road load simulation tests.
Transmission Performance LD
An AVL DynoPrime as a drive unit replaces the ICE or the hybrid propulsion unit. The slim design and short length enable direct mounting to the transmission input shaft, even in a transverse axle arrangement. A powerful engine model enables simulation of the static and dynamic behavior of an ICE. Furthermore, the speed irregularity caused by combustion can also be simulated.
E-Transmission Performance LD
The AVL drive unit covers the desired speed and torque requirements of the replaced e-motor, and must fit into a given installation space. The AVL solution covers the variability of e-axles in a co-axial or offset arrangement, and the connection of e-motor to transmission with intelligent mechanical solutions. An AVL DynoPrime with a slim design and a speed range of up to 20,000 rpm enable direct mounting to the transmission input shaft in a transverse layshaft axle arrangement. A solution using a matching gearbox offers more flexibility and allows e-axle replacement in a co-axial arrangement.
Transmission Performance HD
The AVL drive unit covers the desired speed and torque requirements; the installation space does not need to be considered. Two, four, or more load units with a torque range up to 40,000 Nm are used. Sometimes matching transmissions are necessary to achieve the high torque requirements of the unit under test. The AVL transmission test system solutions also enable HD axle testing.
NVH Testing
The acoustics of the drive unit are optimized to achieve the required noise level. Therefore, the NVH chamber is installed and coupled directly to the transmission. The load units are installed outside the NVH chamber to achieve the ambient noise.
Nothing is more constant than change. As transmission architectures evolve, so must our testing solutions. With AVL’s expertise and reliable systems, our customers can confidently validate performance and focus on what matters most – innovation and development.”
– Dr. Klaus Pfeiffer, System Line Manager, AVL Deutschland GmbH
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.
The market-leading testbed monitoring and control system for a variety of propulsion systems
At AVL, we develop e-axle solutions that can be easily installed without impacting the productivity of your engineering facility.
We offer transmission test systems for various test applications.
With increasingly strict emissions restrictions across the world, and demand for affordable vehicles with low fuel consumption that do not sacrifice comfort, the automotive industry is facing enormous challenges.
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> 70
years of experience
> 5000
employees worldwide for testing solutions
> 30
countries covered by the global network
> 7000
testbeds installed worldwide
> 80
turnkey projects