Electrified Driveline Testing

Millbrook performs electrified driveline testing in 1E, 2E and 3E configurations.

Millbrook has developed significant electric vehicle test capabilities and can support large automotive electric driveline development programmes. High speed, torque and power can be catered for across the passenger car and commercial vehicle markets.

Millbrook can run and manage the full range of tests outlined in ISO 16750 and LV124, giving its customers a ‘one-stop shop’ when it comes to completing a full design verification plan (DVP) for an electric drive system.

Electrified driveline test facility at Millbrook in California with two engineers

Test Facilities

The test facilities are modular in configuration, allowing maximum flexibility when putting together solutions for different test scenarios.

Single machines can be characterised, calibrated and tested for durability against a range of available input machines.

2E configurations with high-dynamic wheel hub output machines are capable of absorbing high torques and speeds while delivering class-leading accuracy in torque and power measurements.

HBM e-drive power analysers are used across the facilities and enable Electric Drive Unit (EDU) manufacturers to quantify efficiency losses through the electric drivetrain.  These analysers measure power from the DC BUS into the power electronics and the e-motor as multiphase AC / pulsed energy, and out to the mechanical drivetrain through the gear set. This gives Millbrook’s customers unparalleled accuracy and high-frequency acquisition of EDU electrical dynamics.

Electric powertrain systems dynamometer test facility at Millbrook in Leyland, UK

Rig Configuration

Power to the DC bus power electronics on a 2E driveline testing rig is provided by scalable 300kW, 1000V, 1000A battery emulators – these systems can also be paralleled to provide more power to power electronics systems if needed.

The rigs can also be configured to run 3E configurations. The input machine of the EDU is replaced by ultra-dynamic synchronous machines.

For fatigue testing, the rigs can be configured to input high torque into a gear set and also shock loading into the wheel-end outputs of an EDU (kerb strike simulation).

High and low voltage electric powertrain systems development testing at Millbrook

Environmental enclosures can be placed around EDU systems to test thermal loading of the EDU and power electronics systems.

Millbrook also caters for mechanical shock, vibration, water and dust ingress and NVH testing of EDU systems.

To complement Millbrook’s test capabilities, a strip and rate facility in the UK provides access to highly specialised camera and lighting equipment. This is used to undertake post-mortem and post-test recording of test samples and their integral components.

Millbrook's Hybrid and Electric Propulsion Test Offering

The following video illustrates some of Millbrook's driveline test capabilities, from battery safety testing (including ECE R100 and UN38.3) to electric car efficiency.