New Energy Vehicle Electric Drive Assembly Performance Testing System

LCCD-001 - New Energy Vehicle Electric Drive Assembly Performance Testing System - Product Background

Overview:

The application of new energy vehicle electric drive assemblies in the automotive industry is increasingly widespread in passenger cars. It is crucial to ensure the performance and quality of the products (motor, controller, transmission) during product development and factory inspection. Therefore, rigorous testing of the performance matching of the electric drive assembly in the whole vehicle system is particularly important. This system conducts type approval tests based on the energy efficiency levels and testing methods of the electric drive motor systems for electric vehicles and electric drive assemblies, as well as referencing other national standards and various assembly testing standards.

Stand photo

Reference Standard:

●GB/T 18488.1-2015 "Electric Vehicle Motors and Their Controllers - Part 1: Technical Specifications"

● GB/T 18488.2-2015 "Electric Vehicle Motors and Their Controllers - Part 2: Test Methods"

Electric vehicle drive motor system and electric drive assembly energy efficiency grade and test methods

●QC/T1022-2015 Technical Conditions for Reducers of Pure Electric Passenger Cars

●GB/T 18385-2005 "Test Methods for Power Performance of Electric Vehicles"

●GB/T 18386-2005 "Test Methods for Energy Consumption Rate and Range of Electric Vehicles"

●GB/T 755-2008 "Rotating Electrical Machines - Rating and Performance Testing Methods"

GB/T 29307-2012 "Test Methods for Reliability of Drive Motor Systems for Electric Vehicles"

●GB/T 22669-2008 "Test Methods for Three-Phase Permanent Magnet Synchronous Motors"

● GB/T 1032-2005 "Test Methods for Three-Phase Asynchronous Electric Motors"

● Specification for Low-Voltage Power Distribution Design - GB/T 50054-95

● General Design Code for Distribution of General Electric Equipment - GB/T 50055-93

● Mechanical manufacturing system in accordance with GB9061-85

●Electrical system in accordance with GB5226-85

LCCD-001 - New Energy Vehicle Electric Drive Assembly Performance Testing System — Topological Structure

Passenger Vehicle Series

Logistics Vehicles, Commercial Vehicles, Heavy Duty Truck Series

LCCD-001 - New Energy Vehicle Electric Drive Assembly Test System features modular and integrated design, with an ergonomically designed operating section capable of manual/automatic mode control. It consists of three parts: the mechanical system, the simulation protection system, the electrical system, and the supervisory software system.

● Mechanical System: Cast iron platform, loading system, quick change fixture system, reversing box, shaft connection parts, and other equipment components.

● Simulation Assurance System: Composed of equipment such as environmental chambers and temperature control systems.

●Electrical System: Comprises bidirectional DC power supply, load controller, sensors (torque, speed, current, voltage, vibration, temperature) with real-time data collection system, data acquisition, current sensor collection, electrical parameter measuring equipment, vibration analysis system, alarm system, and other equipment.

● Software System: The master computer test software is divided into modules such as data collection and communication, data collection settings, real-time data exchange control, and data processing. The master computer completes functions like test control, data analysis and display, data recording, and export based on the test items.

LCCD-001 - New Energy Vehicle Electric Drive Assembly Performance Testing System - System Functions

Passenger Vehicle Frame Test Basic Scope and Accuracy:

● Recommended Power Range: 0~300KW power ratings, with customization available for other power, speed, and torque ratings.

● Recommended output speed measurement range: 0~3300 rpm;

●Recommended output torque measurement range: 0~3,700 N·m

●Recommended Test Voltage Ranges: DC: 0~800~1200V

● Voltage/Current Measurement Accuracy: ±0.01% of reading + ±0.03% of range

●Basic electrical power measurement accuracy: ±0.03%

● Revolution measurement accuracy: ±1r/min

● Torque measurement accuracy: ±0.05% F.S.

Basic scope and accuracy of commercial vehicle chassis testing:

● Recommended Power Range: 0~400~500 kW power ratings, supporting customization for other power, speed, and torque ratings.

●Recommended speed measurement range: 0~2800 rpm

●Recommended Torque Measurement Range: 0~20,000 N.m

Recommended Test Voltage Levels: DC: 0~800~1200V

Voltage/Current Measurement Accuracy: ±0.01% of reading + ±0.03% of range

● Basic electrical power measurement accuracy: ±0.03%

● Rotation Measurement Accuracy: ±1r/min

● Torque measurement accuracy: ±0.05% F.S.

Basic scope and accuracy of logistics vehicle frame testing:

● Recommended Power Range: 0~200KW power ratings, available for customization in other power, speed, and torque ratings.

●Recommended speed measurement range: 0~2000 rpm

●Recommended Torque Measurement Range: 0~3000 N.m

●Recommended Test Voltage Ranges: DC: 0~800~1200V

Voltage/Current Measurement Accuracy: ±0.01% of reading + ±0.03% of range

● Basic electrical power measurement accuracy: ±0.03%

● Rotation Measurement Accuracy: ±1r/min

● Torque measurement accuracy: ±0.05% F.S.

Heavy-duty truck frame testing basic scope and accuracy:

● Recommended Power Range: 0~500~800 kW power ratings, with customization available for other power, speed, and torque ratings.

●Recommended Speed Measurement Range: 0~2000 rpm

●Recommended Torque Measurement Range: 0~20,000 N.m

Recommended test voltage level: DC: 0~800~1200V

Voltage/Current Measurement Accuracy: ±0.01% of reading + ±0.03% of range

● Basic electrical power measurement accuracy: ±0.03%

● Rotation Measurement Accuracy: ±1r/min

● Torque Measurement Accuracy: ±0.05% F.S.

Test Items:

Complete Assembly Load Test, Complete Assembly No-Load Test, Complete Assembly Temperature Rise Test, Efficiency Characteristics Test (Torque-RPM Characteristics), Reliability Test (Durability Test), Electric Operating Conditions, Generator Operating Conditions, Efficiency MAP Chart, etc.

LCCD-001 - New Energy Vehicle Electric Drive Assembly Performance Testing System - Key Features

01 Modular Functions

All rig constructions are modularized for easy assembly, allowing for the integration of various test modules into a single testing system. Customers can add or remove test modules based on the specific test object.

02 Advanced measurement methods

Utilizing advanced real-time measurement and control systems, including input electrical parameter testing and rotational speed/torque testing, with a sampling rate of up to 1000Hz for torque and speed, meeting the high precision and rapid response requirements of the testing system. It also provides transient and characteristic value data, facilitating comprehensive analysis of test process data by software in the post-processing phase.

03 Comprehensive Test Items

In accordance with the national standards' testing requirements, the test items can be added or reduced based on the configuration modules, and can meet the requirements for various types of testing.

04 Environmental Simulation Equipment

Utilizing a refrigeration and heating mode with compression technology for the environmental simulation equipment and temperature control system of the test piece, it shortens the aging durability test time of the test piece by simulating high and low temperatures, as well as high and low humidity environments, thereby enhancing overall research and development efficiency and reducing the development cycle.

05 Motor Load

Utilizing an asynchronous motor as the test electric drive assembly's load, this approach changes the traditional loading method, enhancing the system's dynamic torque and speed measurement range and precision, improving loading performance (forward/reverse, reverse drag), reducing the response time for loading, and enabling the loading of any desired load curve, closely simulating the real-time operating conditions of the electric drive assembly.

06 User-friendly Design

Utilizing a professional motor testing bench, the fixtures feature rapid connection capabilities and are easy to assemble and disassemble, accommodating various test pieces. The system operates with a console or cabinet + computer desk control mode, enabling the completion of all test operations at a single location.

07 Customized Test Software

Motor Test System Test Software developed by Suzhou Lice Software R&D Team, adhering to national standards for test items, categorizes the software interface and processes to minimize redundant testing, significantly enhancing the efficiency of test personnel. It also features real-time curve plotting, transient value capture, trend curve drawing and analysis, multi-parameter combination display, pass/fail judgment, and report export functions.

LCCD-001 — New Energy Vehicle Electric Drive Assembly Performance Testing System — Main Applications

● Passenger Vehicle Electric Drive Assembly

Commercial Vehicle Electric Drive Assembly

● Electric Drive Assembly for Logistics Vehicles

Heavy-duty truck electric drive assembly