Powertrain Testing Solutions

A versatile test system (TS) for validating pure ice and electrified propulsion systems.

Our powertrain testing solutions are designed to support the complex validation of internal combustion engine (ICE) vehicles and electric vehicles (EVs), including hybrid EVs, plug-in hybrid EVs, battery EVs, and fuel cell EVs, through all stages of development.

With extensive experience in developing powertrain test solutions for passenger cars, light and heavy trucks, buses, tractors and off-road vehicles, AVL offers comprehensive solutions that span the entire development process. Our versatile test systems are designed for a wide range of applications.

Typical powertrain tests include durability testing to meet specific component life targets, performance evaluation, fuel consumption optimisation, emission control and electric range extension. We also focus on drivability optimisation, integration of high voltage (HV) components, on-board diagnostics and fault diagnosis. In addition, we perform safety-critical testing to ensure that unforeseen interactions do not lead to undefined operating conditions.

Complexity of Powertrains

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 advanced 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.

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.

Our Solutions for Transmission Testing

Performance Testing LD
Two or four dynamometers with a torque range of 3,200 Nm to 7,000 Nm with an output of 220kW up to 500kW are mounted directly at the wheel hub. A battery emulator with an output of up to 1,000kW typically replaces the battery in an electrified propulsion system. A powerful vehicle dynamics simulation enables driving maneuvers in various driving conditions.

Performance Testing HD
Two, four, or more dynamometers 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. A battery emulator with an output of up to 1,000kW typically replaces the battery in an electrified propulsion system. A powerful vehicle dynamics simulation enables real-world driving maneuvers.

NVH Testing
Two or four dynamometers are used to load the propulsion system. The dynamometers are installed outside the NVH chamber to achieve the ambient noise.

System Integration, HV Integration
The basis for the test system is a highly automated propulsion test system with four high-dynamic wheel dynamometers. It also offers several conditioning devices, load units, and measurement equipment for rotational speed, torque, temperature, etc. Thus, a high number of tests can be executed and repeated in a short time. To address the needs of HV electrified propulsion system validation, the test system is extended with additional testing equipment, such as high-power HV sinks/sources, measurement systems with high sampling rates for voltage and current, and mains emulation.

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

Advanced Propulsion System Testing Solutions

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.

Portfolio

AVL E-STORAGE SiC™

Battery tester and emulator for research and development, testing and validation.

AVL CONCERTO

Transform your e-mobility analysis with AVL CONCERTO 6™, featuring fast data access, AI-driven technologies, advanced visualizations and calculations, and auto-generated reports for superior performance and precise insights.

AVL E-STORAGE BTE™

Battery tester and emulator for research and development, testing, and validation purposes.

AVL M.O.V.E PM PEMS iX

Portable on-board soot and PM measurement device.

AVL E-STORAGE LV™

Highly dynamic, regenerative power supply optimized for the testing of low-voltage micro and mild hybrid systems.

Global Presence

Your reliable global partner in powertrain testing solutions

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

> 5000

employees worldwide for testing solutions

> 30

countries covered by the global network

> 7000

testbeds installed worldwide

> 80

turnkey projects