Development Dyno Electric Vehicle Motor
Eagle designed this Dynamometer for:
- TCU transmission shift characterization and validation.
- Design validation for testing purposes.
- Complete electric vehicle environmental test simulation including vehicle inertia, shifting, braking, and road sims.
- Advanced development for shifting times, shifting logic, shifting timing, shifting smoothness, limp mode, and durability testing.
Program Execution
Challenge
- EV Cooling System (part and controller)
- Advanced test hardware and software
- Protection of the part (motor) and the dyno
- Maximize safety
Solution
- Custom mechanical design to protect the part and the machine
- Bauer partnership with Eagle in custom software design
- Motor and drive emulation
Results
- Satisfied customer and successful project execution
- Exceeded test requirements of 2500 Nm and 3300 RPM
- Completely dynamic advanced software and hardware methods
MOTOR (PART) CHARACTERISTICS
Technical Characteristics
- Multi-mode powertrain
- Two sets of ratios
- Motor A
- 1st Gear 3.63:1, 2nd Gear 1.72:1 3rd Gear 1:1
- Motor B
- 1st Gear 2.64:1, 2nd Gear 1:1
- Motor A
- 250 ms shift times with no torque interruption
Key Market Characteristics
- All Electric – no hydraulic
- Several markets of use:
- Class 1-8 trucks
- Light-duty trucks and SUV’s
- Light military trucks
- Input max torque 4000 Nm
Special Designs
- Compact motor design (13″ long)
- Modularity in design:
- Dual motor configuration
- Versatile and services the need of many applications using one size fits all design philosophy
DYNO TEST CHARACTERISTICS
Test Capabilities
- Continuous 2500 Nm
- Maximum RPM 3300
- Torque transducer resolution
- .03% Error, 18,000 RPM, 10 kNm Full scale, 1024 TTL RPM Feedback
- Dynamic torque feedback
- Speed and torque modes
- Optimized analytics EV Testing
- Developed:
- Shifting logic
- Shifting times
- Shifting smoothness
- Limp mode
- Durability testing
Hardware & Controls
- 4-door 480 VAC Panel
- 700 VDC Power Supply Battery Emulation
- Cooling System:
- 250+ KW Heat Removal (Glycol)
- Part Oil Cooler
- Bauer & Custom Drivers
- Direct Control of Dyno
- Sample Rate < 5 ms
Bringing a new product to the market can always be challenging. The dynamometer requirements were a challenge, and Eagle met all our expectations. The dyno design is robust, the software is streamlined, and the build quality is world-class. Thank you, Eagle.
EV Powertrain Company
ADVANCED TEST SYSTEMS
Eagle Technologies provides a turnkey solution for businesses seeking an all-in-one solution to automated production and testing. While many industries separate product manufacture from product testing, we do both. We believe that if we are going to build machines to manufacture your products, we should also be the ones testing the products to be sure the final output meets the design requirements.
Our testing systems go above and beyond standard implementation. Using the most advanced emerging technologies, including NVH, Dynamometers, simulation, augmented reality, prototype engineering, and 3D additive manufacturing, our autonomous systems can measure variables and correct in real time, leading to increased performance with reduced costs.
Lets Talk.
Contact us and we’ll be happy to help!