High-Performance 2E Hybrid Powertrain Engine Test Cell at Millbrook with engineers performing engine testing and hybrid powertrain testing

2WD Powertrain Test System

This facility is ideally suited for testing high-performance engines and complex hybrid powertrains.

 It has two hub-mounted, high dynamic dynamometers and a 300kW battery simulator. It is self-contained and totally secure with its own control room.

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Hybrid Powertrain Test Facility

  • System nominal power absorption 700kW
  • Dyno inertia 0.84kgm²
  • 2x ultra-dynamic synchronous motors; 350kW, 3,500Nm (+20% overload)
  • Transient overload to 840kW/8,400Nm
  • Maximum speed 3,000 min-1
  • Dynamic torque changes performed at minimum 0.13ms
  • 300kW Battery Simulator (1,000V/600A)
  • ETAS Inca ECU calibration tools with iLinkRT real-time interface
  • Modelling and Simulation realised through Mathworks and dSPACE software integration
  • Cell and engine intake air control between 20°C to 35°C +/- 2°C
  • Engine coolant control to +/- 1°C
  • Test bench intercooler temperature control to +/-1°C
  • AVL Fuel Exact measurement with temperature conditioning
  • Measurement of 70 temperatures and 32 pressures
  • Additional analogue and digital input/output channels available

Applications

  • Powertrain-in-the-Loop (PIL) simulation and test capability
  • IC or hybrid emissions development, including simulation of real world and regulated cycles
  • Test of powertrain with a virtual battery using the battery simulator
  • EDU and e-axle functional development and durability
  • Powertrain control strategy development
  • Hardware integration testing
  • Development of low maturity hardware using Hardware-in-the-Loop simulation (HIL)
  • Engine and transmissions thermal studies
  • Development of traction control systems using fully integrated tyre slip models
  • Mule use of components to simulate future vehicles
  • Condensed testing on a rig compared to track or road-based testing
  • Highly repeatable measurement of fuel consumption, emissions and energy consumption

Contact us now for more information on the high-performance hybrid powertrain test cell.

Millbrook has 28 engine test cells in the UK covering a diverse range of capabilities, with latest test cell automation software and hardware and up to 2.1MW dynamometers.

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