This document presents the concept development for a new universal powertrain test rig for the Institute of Vehicle Technique at TU Dresden. The goal was to create a test rig that can test modern powertrain elements and systems based on increasing requirements. A literature review and market analysis of existing test rigs and vehicle parameters was conducted to determine necessary test rig capabilities and specifications. An operation concept was developed outlining possible tests. A structural concept was presented and components were selected that met the defined requirements specification. Control schemes were developed for operating the test rig. The conclusion was that the new concept test rig design would satisfy the goals of testing modern powertrains and their components more flexibly and with higher capacity than existing test rig

1. Fakultät Verkehrswissenschaften „Friedrich List“ - Institut für Automobiltechnik Dresden - IAD
Lehrstuhl Kraftfahrzeugtechnik
BACHELOR THESIS
to obtain the academic degree
Bachelor of Science (B. Sc.)
Powertrain test rig application analysis and concept
development
Editor
Aleksejs Davidovs
Matriculation number
3937531
Born on
03.03.1989 in Daugavpils, Latvia
Supervisors
Dipl.-Ing. Kay Büttner - IAD
Dipl.-Ing. Pavel Sarkisov – IAD
Dr.sc.ing., doc. Guntis Strautmanis – RTU, Latvia
Supporting high school teacher
Prof. Dr.-Ing. G. Prokop
Date of submission:
01.06.2013

2. TECHNISCHE
UNIVERSITÄT
DRESDEN
Institut für Automobiltechnik Dresden - lAD
Lehrstuhl Kraftfahrzeugtechnik
Bachelor thesis mission statement BAK 2013-01
Student:
Imm. Num.:
Davidov, Alexey
3937531
Course of studies: Mech. Engineering, Automotive engineering
IRD
Theme: Powertrain test rig application analysis and concept development
In spite of growing quality of simulation, application of test rigs still is apart of modern re-
search-and-development techniques. On the contrary increasing the model complexity and
consequent growing requirements to the parameterization process lead to stronger necessity
of high-precision test rigs. Powertrain testing incorporates a lot of areas. The scope of a de-
sign layouts varies from gear interaction up to complete powertrain. The goal of the project is
development of reasonable testing concept and implementation scheme for powertrain test
rig in lAD. For this purpose the development process should be started with literature analysis
in order to structure initial areas of information, hence specific requirements list should be
prepared. In addition estimation of performance and occupied space is to be performed in
connection with investment analysis. To summarize, realization concept should be created
based on cost-benefit consideration taking into account current and future research areas of
the chair. Therein the main components of the test rig should be defined, dimensioned and
selected. As weil the signal routing scheme is necessary as a foundation for further pro-
cessing. The thesis must be documented in accordance with the directive of Scientific De-
partment.
Following activities are to be performed:
Literature analysis of powertrain testing field of study
Operation concept development
Preparation of requirements specification
Development and estimation of implementation concept
Defining, dimensioning and selecting the test rig components
Development of signal routing scheme for test rig control
Documenting the results
Supervisor:
issued:
submitted:
Kay Büttner (TU Dresden), Pavel Sarkisov (TU Dresden)
March 01 , 2013
July 01, 2013
Prof. Dr.-Ing. Günther Prokop
(responsible university professor)

3. BAK 2013 - 01 Abstract
Abstract
In TU Dresden Institute of Vehicle Technique reorganisation of laboratories occurs, within which is
planned to replace an old test rigs with a new ones, in particular a powertrain test rig.
This thesis deals with development of a concept of universal powertrain test rig for passenger car power-
train system testing. Analyse of existing modern powertrain test systems and passenger vehicle market
gives information about necessary parameter values and equipment for developed powertrain. Operation
concept development gives information about range of possible tests developed concept will provide. De-
velopment and estimation of implementation concept gives information about necessary equipment for
developed test rig and also about its structure for ability to implement all kinds of tests. Requirement
specification development gives information about definite required physical and geometrical values of
developed test rig concept elements. Development of schemes for test rig control gives information about
the organization of management, power supply, cooling supply, energy recuperation, etc. in developed
powertrain test rig.
Anotācija
TU Drēzdene Automobiļu transporta institūtā notiek laboratoriju reorganizācija, saistībā ar kuru tiek plā-
nota visas vecas testēšanas aparatūras maiņa uz jaunu, tajā skaitā arī transmisijas testēšanas iekārtas.
Dotajā diplomdarbā tiek aprakstīta universālas pasažieru automobiļu transmisiju testēšanas iekārtas kon-
cepta izstrāde. Esošo moderno transmisiju testēšanas iekārtu un pasažieru automobiļu tirgus analīze dod
informāciju par svarīgo parametru lielumiem un par aparatūru, kas ir nepieciešama izstrādājamai testēša-
nas iekārtai. Operāciju koncepcijas izstrāde dod informāciju par testiem, ko projektējamai iekārtai jāno-
drošina. Koncepcijas realizācijas izstrāde dod informāciju par aparatūru un tās sakārtojumu, kas ir nepie-
ciešami lai nodrošinātu visu testu veidu realizācijas iespēju. Prasību specifikācijas izstrāde dod informāci-
ju par noteiktiem vajadzīgiem fiziskiem un ģeometriskiem testēšanas iekārtas elementu lielumiem. Testē-
šanas iekārtas kontroles shēmu izstrāde dod informāciju par vadības, elektroapgādes, dzesēšanas, enerģi-
jas rekuperācijas u.c. realizāciju.
IAD – TU Dresden IV

4. BAK 2013 - 01 Table of contents
Table of contents
List of Figures ........................................................................................................................................... VII
List of Tables.............................................................................................................................................. IX
Designations.................................................................................................................................................X
1 Introduction..............................................................................................................................................1
2 Theoretical substantiation ........................................................................................................................2
2.1 Types of transmission failures and causes of the necessity of testing............................................. 2
2.2 Vibrations in powertrains, their measurement using powertrain test rigs ....................................... 3
2.3 Advantages and features of testing using powertrain test rigs ........................................................ 5
2.4 Testing of HEV powertrains............................................................................................................ 8
3 Market analysis ......................................................................................................................................10
3.1 Analysis of the proposal of powertrain test rigs............................................................................ 10
3.1.1 Powertrain test systems with ICE and wheel replacement tools.............................................11
3.1.1.1 AVL Driveline test bed, Model DRS370 ....................................................................... 11
3.1.1.2 TMG Transmission test system...................................................................................... 13
3.1.1.3 SuperFlow Transmission dynamometer, Model AXILINE 97000................................. 15
3.1.1.4 TU Stuttgart powertrain and hybrid test system............................................................. 18
3.1.1.5 MAE Universal Transmission Dynamometer, Model LDU-40 ..................................... 19
3.1.2 Powertrain test systems for entire cars. MTS Spindle-Coupled Road Simulators,
Model 329 Multiaxial .............................................................................................................22
3.1.3 Powertrain component test systems........................................................................................23
3.1.3.1 LINK Transmission torque cycling durability machine, Model 2090............................ 23
3.1.3.2 LINK Automatic transmission high speed test system, Model 2190 ............................. 24
3.1.3.3 LINK Wet friction test stand, Model 3100..................................................................... 25
3.1.3.4 MAE Transmission solenoid tester, Model ST1000 ...................................................... 26
3.1.3.5 MAE Transmission valve body tester ............................................................................ 27
3.1.4 Summarizing of information about powertrain test rigs.........................................................27
3.1.5 Dynamometers for powertrain test rigs...................................................................................30
3.2 Analysis of the demand of powertrain test rigs ............................................................................. 35
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5. BAK 2013 - 01 Table of contents
4 Operation concept development.............................................................................................................40
4.1 Overview of the necessary sensors and equipment ....................................................................... 40
4.2 Description of powertrain tests...................................................................................................... 41
4.3 Summarizing of powertrain test rig operations ............................................................................. 47
5 Development and estimation of implementation concept ......................................................................48
6 Requirement specification......................................................................................................................51
7 Defining, dimensioning and selecting test rig components....................................................................58
8 Development of signal routing scheme for test rig control....................................................................65
9 Conclusions............................................................................................................................................70
List of References........................................................................................................................................72
Appendix........................................................................................................................................................i
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6. BAK 2013 - 01 List of Figures
List of Figures
Figure 3.1: Designations for powertrain test rig schemes ...........................................................................10
Figure 3.2: AVL Driveline test bed, Model DRS370 [2]............................................................................11
Figure 3.3: Main parameters of AVL Driveline test bed, Model DRS370 .................................................11
Figure 3.4: AVL Driveline test bed, Model DRS370 scheme.....................................................................12
Figure 3.5: TMG Transmission test system [42].........................................................................................13
Figure 3.6: Main parameters of TMG Transmission test system ................................................................14
Figure 3.7: TMG Transmission test system scheme ...................................................................................14
Figure 3.8: SuperFlow Transmission dynamometer, Model AXILINE 97000 [38] .................................15
Figure 3.9: Main parameters of SuperFlow Transmission dynamometer, Model AXILINE 97000...........16
Figure 3.10: SuperFlow Transmission dynamometer, Model AXILINE 97000 scheme..........................16
Figure 3.11: TU Stuttgart powertrain and hybrid test system [8]................................................................18
Figure 3.12: Main parameters of TU Stuttgart powertrain and hybrid test system.....................................18
Figure 3.13: TU Stuttgart powertrain and hybrid test system scheme ........................................................19
Figure 3.14: MAE Universal Transmission Dynamometer, Model LDU-40 [32] ......................................20
Figure 3.15: Main parameters of MAE Universal Transmission Dynamometer, Model LDU-40..............20
Figure 3.16: MAE Universal Transmission Dynamometer, Model LDU-40 scheme.................................21
Figure 3.17: MTS Spindle-Coupled Road Simulators, Model 329 Multiaxial [24]....................................22
Figure 3.18: LINK Transmission torque cycling durability machine, Model 2090 [20] ............................23
Figure 3.19: LINK Automatic transmission high speed test system, Model 2190 [18]..............................24
Figure 3.20: LINK Wet friction test stand, Model 3100 [21] .....................................................................25
Figure 3.21: MAE Transmission solenoid tester, Model ST1000 [32] .......................................................26
Figure 3.22: MAE Transmission valve body tester [32] .............................................................................27
Figure 3.23: New passenger car sales in Europe and World [10], [22].......................................................35
Figure 3.24: Average wheelbase and tracks values of sold new passenger car in Europe [10], [22]..........36
Figure 3.25: Average engine power in sold new passenger cars in Europe [10], [22]................................36
Figure 3.26: Sold new passenger cars in Europe: Market share by drive [10], [22] ...................................37
Figure 3.27: Sold new passenger cars in Europe: Market share by fuel type [10], [22] .............................37
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7. BAK 2013 - 01 List of Figures
Figure 3.28: Sold new passenger cars in Europe: Market share by transmission type [46]........................38
Figure 3.29: What do people expect from a car in 25 years' time? [53]......................................................39
Figure 5.1: Developed test rig’s structural scheme .....................................................................................50
Figure 7.1: AVL DYNOEXACT APA 802/12 Gx technical data (part 1) [3]............................................59
Figure 7.2: AVL DYNOEXACT APA 802/12 Gx technical data (part 2) [3]............................................60
Figure 7.3: SIEMENS 1HS6286-0ND40-2YV1 technical data (part 1) [36]..............................................61
Figure 7.4: SIEMENS 1HS6286-0ND40-2YV1 technical data (part 2) [36]..............................................62
Figure 7.5: TECHNOGERMA EDDY>TEC 2101/110 technical data [40] ...............................................63
Figure 8.1: Developed test rig control signal routing scheme.....................................................................65
Figure 8.2: Developed test rig measuring equipment connection scheme ..................................................66
Figure 8.3: Developed test rig current supply and recuperation scheme.....................................................67
Figure 8.4: Developed test rig water cooling supply scheme......................................................................68
Figure 8.5: Developed test rig HF and ATF supply scheme .......................................................................69
IAD – TU Dresden VIII

8. BAK 2013 - 01 List of Tables
List of Tables
Table 2.1: Powertrain based testing (a kind of method of HEV testing using powertrain test rig)[35]........9
Table 3.1: Specification of powertrain test rigs...........................................................................................29
Table 3.2: Specification of electric motors, used in powertrain test rigs ....................................................32
Table 3.3: Specification of electric motors, proposed on market................................................................33
Table 3.4: Highest parameters of passenger cars [45], [47], [52] ...............................................................35
Table 4.1: Information about sensors and measured parameters.................................................................41
Table 6.1: Requirement specification..........................................................................................................51
Table 7.1: AVL DYNOEXACT APA 802/12 Gx comparison with requirement specification ................61
Table 7.2: SIEMENS 1HS6286-0ND40-2YV1 and TECHNOGERMA EDDY>TEC 2101/110
comparison with requirement specification...............................................................................64
IAD – TU Dresden IX

9. BAK 2013 - 01 1 Introduction
1 Introduction
Modern mechanical engineering has high dynamics of development of various technologies. Automobile
corporations seek to improve the comfort, safety, handling, dynamics, and other characteristics of their
vehicles. Existing technologies and equipment allow considerably improve all vehicle systems. In spite of
this, every year new systems, components and devices, including those relating to the powertrains, are
being developed.
Phases of design and development of automotive transmission components are generally long and expen-
sive. Car manufacturers and vehicle equipment manufacturers are permanently looking for other solutions
in order to reduce time and cost of development phases [34].
For systems debugging, malfunctions detecting and important parameters and characteristics determining,
it’s necessary to produce different kinds of tests. There are various test rigs that allow making wide range
of tests of various powertrains’ configurations and components. Every test rig has its advantages and dis-
advantages however they are limited in their functionality. Therefore, it makes sense to create a universal
test rig that has a maximal number of positive features of existing analogues. Developed concept certainly
will be actual considering trends in environmentally-friendly system development, and with it different
from its predecessors, types and configurations of powertrains.
In TU Dresden Institute of Vehicle Technique reorganisation of laboratories occurs, within which is
planned to replace an old test rigs with a new ones, in particular a powertrain test rig. The basic areas of
improvement:
− capacity (opportunity of testing modern powertrain elements and systems, considering modern
values of dynamic characteristics),
− flexibility (opportunity of making maximal amount of tests of different system layouts with dif-
ferent geometrical parameters, and also system separate parts),
− actuality (opportunity to test technologies of near future, at least developed at the moment and
already planed).
Considering all told above one can conclude the following bachelor thesis goal: development of a con-
cept of universal powertrain test rig for passenger car powertrain system testing.
To achieve the goal, the following objectives were defined:
− market analysis with goal to determine powertrain manufacturer requirements and test rig devel-
oper offers,
− development of a powertrain test rig concept that satisfies maximal amount of powertrain manu-
facturer requirements.
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10. BAK 2013 - 01 5 Development and estimation of implementation concept
Figure5.1:Developedtestrig’sstructuralscheme
IAD – TU Dresden 50

11. BAK 2013 - 01 9 Conclusion
9 Conclusions
New concept of powertrain test rig for renovated TU Dresden laboratory is developed and described in
detail. During the work elaboration was made detailed analyse of nowadays existing powertrain test rigs,
their strong and weak sides were found and summarized. As well detailed analyse of vehicle sales was
made, what gave ability to take into account consumer needs. As a result, developed concept has follow-
ing features:
− 4 output drives, made of DC motor + EC brake each,
− movable frame for every drive,
− powerful electric motors with low inertia in every drive,
− centralised water cooling system,
− centralised HF supply system,
− big baseplate with slots for equipment mounting on all baseplate space,
− road simulators for every wheel with ability to move in 6 directions and turn,
− exhaust ventilation and additional movable frame for ICE mounting,
− range of actuators for gearboxes,
− range of mounting devices.
Described concept features provide following advantages:
− possibility to test all powertrain configurations – all FWD, RWD and AWD configurations and
all HEV configurations,
− possibility to test most powertrain elements separately – gearboxes, axles, differential etc.,
− environmental-friendly testing,
− possibility to change drive position for testing different sizes of powertrains without drive dis-
mounting from baseplate,
− easy-manageable testing,
− possibility to test powertrain systems for powerful vehicles, partly for sport cars, luxury cars and
even super cars,
− less noise from cooling system,
− less space for cooling and HF supply systems,
− possibility to configure test rig for special tests by replacing all testing equipment almost free,
− ability to change every wheel position during tests for more precise real driving condition
simulation,
− possibility to make tests with ICE,
− possibility to test all kinds of gearboxes,
− high test rig “flexibility”,
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12. BAK 2013 - 01 9 Conclusion
− possibility to make most kinds of tests of powertrain systems and their elements,
− easy powertrain element mounting and dismounting,
− preparedness to adapt for testing future technologies,
− possibility to recuperate part of used energy.
Marked advantages are uncommon for powertrain test rigs even nowadays. Possibility to change wheel
positions has TMG company’s test rig, described in Chapter 3, but it’s developed for testing only FWD
and RWD configurations. Possibility to recuperate part of used energy is unique for powertrain test rigs.
It will make developed concept really unique and unusually clean.
Developed concept will be best on the market because it includes all advantages of modern powertrain
test rigs and its element’s values are higher than another powertrain test rigs have. Concept also will sat-
isfy most client needs – in some aspects it will satisfy 100% of client needs (e.g. powertrain configura-
tion, type of gearbox), in another it will satisfy ~ 70-90 % of client needs (e.g. maximal continuous power
or torque, provided by motor).
As a recommendation should be mentioned possibility to place part of test rig equipment to another room,
near or under the test rig, e.g. water cooling and HF supply systems’ pumps and tanks, torque converters,
PLCs etc. It will decrease level of noises and vibrations of powertrain test rig and will increase test accu-
racy and also ergonomics.
IAD – TU Dresden 71

13. BAK 2013 - 01 List of References
List of References
[1] ANTRIEBSTECHNIK KATT HESSEN: Hauptantriebsmotoren, Homberg/Efze, DE, 2012
[2] AVL LIST GMBH: Driveline test bed “Powertrain in the loop”, Graz, AT, 2009
[3] AVL LIST GMBH: DynoExact APA (top accuracy AC dynamometers), Graz, AT, 2009
[4] AVL LIST GMBH: DynoPerform (Eddy Current dynamometers), Graz, AT, 2009
[5] AVL LIST GMBH: DynoPrime (AC motors for engine simulation), Graz, AT, 2009
[6] AVL LIST GMBH: DynoTrain AFA-T (modular system of AC motors for multi-drive solu-
tions), Graz, AT, 2009
[7] AVL LIST GMBH: DynoWheel PMM-T (ultra low inertia AC drives for powertrain test cells),
Graz, AT, 2009
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[20] LINK ENGINEERING COMPANY: Transmission torque cycling durability machine (Model
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2012
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14. BAK 2013 - 01 List of References
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15. BAK 2013 - 01 List of References
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IAD – TU Dresden 74