ROTOTEST Energy

Flexible Powertrain Chassis Dynamometers

Hub-Mounted Chassis Dynamometerswith Steering Operation Capability

PRODUCT BROCHURE

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Minimum Preparation Time and Reliable RepeatabilityNew Paradigm for “Road Load Simulation Testing” is here

MINIMUM INFRASTRUCTURE REQUIREMENTSCompared with conventional roller-type chassis dynamometers (CDM) (see figure 1), the ROTOTEST Energy system does not require a large facility such as an underground pit. With a level floor plan (e.g. garage) (see figure 2) and power (@400V, 3 phase) being the main requirements, a full battery of tests can be carried out. This dramatically lowers cost and provides flexibility.

Note: Additional equipment may be needed to support the ROTOTEST test environment. This includes (but not limited to) cooling and exhaust infrastructure.

SHORT SET UP TIMEWhen using other hub-mounted chassis dynamometers, it can take an inordinate of amount of preparation time to ready a vehicle for testing. However with ROTOTEST, you can be ready for testing (see figure 3) in the same amount of time required to install four common tires. Please note set up times are based on information from OEM’s and Engineering Consultants.

ROTOTEST Energy CompetitorsSet up time 10-15 minutes 3-6 hours

Time to remove 10-15 minutes 30-60 minutes

Number of operator(s) 1-2 2-4

Operation rate per day

(assume 2h/test, 7h/days)about 86% about 29%

EASY TO SETUP

Please visit our the ROTOTEST microsite on our website for further information including links to demonstration videos. https://toyotechus.com/automotive_measurement/powertrain_and_chassis

COST-EFFECTIVE

Figure 2: ROTOTEST

Figure 1: Conventional Roller-Type CDM

ROTOTEST Competitor 7 hours / day

Test

Set-up / Remove

Figure 3: Comparison of Set up and Operation Times

PERFORM/VALIDATE EPA CERTIFICATION REQUIREMENTS

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ROTOTEST Hub-Coupled Chassis Dynamometer

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MODULE FOR VARIOUS TEST REQUIREMENTS By utilizing a state of the art 4Q control system and the ROTOTEST Active Inertia technology, the vehicle’s inertia can be simulated electronically to replicate true road conditions. In addition to being able to simulate different types of driving patterns, each tire can be modeled using a “magic formula” (see figure 4).

� Constant torque, constant speed � Sweep � Road load simulation � Individual torque control, etc.

STEERING OPERATION CAPABILITY Due to its unique structure, ROTOTEST Energy provides a bench test with steering operations. This is something not typically achievable with conventional CDM. The steering angle can be rotated to +/- 20 degrees (see figure 5). You can simulate driving situations including steering operation, evaluate for ADAS, autonomous car, etc.

MEASUREMENT SYSTEM WITH HIGH ACCURACY AND REPEATABILITY When it comes to conventional roller-type chassis dynamometers, measuring torque directly in the hub position brings many advantages including high accuracy and constant repeatability. With no interference (see figure 6) from the automobile’s tires, this system achieves high repeatability, which is important for performing benchmark testing. In addition, this unit can be automatically tilted in order to adjust the torque measurement line. Also see figures 7 and 8.

Power consumption measurement of headlight (@ 30km/h, low / high beam)

EXPANDABLE TEST MODULE

CRITICAL MEASUREMENTS

DirectCoupling

PowertrainChassis Dynamometer

Figure 6

STEERING OPERATION

Figure 4: Real-time Torque Distribution

Figures 7 & 8

Figure 5: Steering Controls

PERFORM AND VALIDATE EPA CERTIFICATION REQUIREMENTS Rototest Dynamometers support EPA driving cycles such as FTP and US06. And the requirements for tolerances and response. Furthermore, the solution can be used for certification testing according to Federal Regulation 40 CFR Part 86 Section 86.108.

BUILT-IN TORQUE TRANSDUCERA torque transducer built into the hub to perform torque measurements. This is a patented design. In addition, calibration information is stored locally on the dynamometer unit.

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DMTS Driving & MotionTest System

ENGINEERED BY TOYO The Driving & Motion Test System (DMTS) is engineered by TOYO. It is a next generation driving test system with a steering function that allows for autonomous vehicle testing and development.

The DMTS that can perform driving tests equivalent to actual roads in the laboratory making it possible to perform the final step in the “Model Based Development” (MBD) framework in a fully controlled evironment and eliminate the challenges associated with the last steps of traditional MBD.

VEHICLE DYNAMICS SIMULATOR Through the employment of vehicle motion simulation software, TOYO’s Vehicle Dynamics Simulator provides a comprehensive virtual environment/scenario to the test environment on the CDM to offer a real-time simulation environment that includes vehicle motion. This capability can bridge the gap between a simulation-based testing environment and real-world one.

STEERING ASSISTANT SYSTEMAn steering assistant system is an optional add on to the ROTOTEST dynamometer in order to reproduce steering reaction force in a very precise fashion. In such a configuration, simulated lane changes that permit you to exhaustively test and evaluate ADAS and autonomous vehicle driving scenarios can be performed in the lab setting.

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ROTOTEST Hub-Coupled Chassis Dynamometer

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ROTOTEST500 KW - 250 KW MODEL FOR ROAD LOAD SIMULATION ROTOTEST Energy 500-250 4WD consists of each 500 kW, 250 kW dynamometer axle. It can be used for 4WD and 2WD depending on the vehicle under test. Because of its repeatability, accurate results can be obtained from the benchmark test. Several power models are available depending on your specified requirements.

BUILT-IN CLIMATE PROTECTION (CP) MODEL (-31° TO 105° F; -35° TO 40° C) This model has an expanded operational temperature range of -31° to 105° Fahrenheit (-35° to 40° Celsius). Given sufficient space, this system can be used in an existing climate chamber. The steering operation also can be used in very low temperature environments allowing you to evaluate how vehicles respond in such harsh conditions (see figure 13).

APPLICATION EXAMPLE: ENERGY FLOW MANAGEMENT EVALUATIONThis graph on the right (see figure 13) shows power consumption for an air conditioner. Running a gasoline engine at 1,500 rpm, “A/C power consumption” + “generator loss” can be measured as a power difference. Due to accurate torque measurements with the hub mounted ROTOTEST Energy, energy flows can be characterized accurately.

APPLICATION EXAMPLE: INDIVIDUAL WHEEL TORQUE CONTROL You can control each wheel’s torque individually with the dynamometers connected directly to each wheel. The left graph below (see figure 10) shows the torque distribution when all tires except the front left one drives on a snow covered road. The right graph below (see figure 11) represents the situation when turning the steering wheel. By defining a vehicle’s mass and μ of each tire, the running resistance can be simulated (see figure 12). For example, the condition where some specific tires are on different road conditions can be simulated.

Figure 10: Torque Distribution in Snow Covered Road Scenario

Figure 11: Torque Distribution during Steering

Figure 12: Running Resistance Simulation

Figure 13: Power Consumption with Air Conditioner On

Standard Model

ROTOTEST Climate Model

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LOW NOISE MODEL FOR NOISE, VIBRATION, AND HARSHNESS (NVH) TESTEven very low noise levels can negatively impact NVH measurements. Compared with traditional roller type dynamometers, there is next to no tire noise generated by the ROTOTEST units.

ROTOTEST Energy NVH can be customized by removing blowers for cooling and covered with sound insulation boxes. The model can also be installed in semi-anechoic chambers.

APPLICATION EXAMPLE: NVH TEST Operational noise driving at 100 km/h (62 mph)is only about 45 dBA. Therefore you can evaluate NVH phenomena which are usually buried in noise coming from tires. In addition, there is no need to bind the vehicle. So it is possible to minimize changes to the NVH character due to binding. Refer to figure 14.

Examples include:

� Evaluating noise from EPS

� Precise noise measurement (intake / exhaust, powertrain, etc.)

� Contribution analysis in indoor pass-by noise test

Overall Noise

Tire Noise

IC Noise

ROTOTESTis less than45 dBA even @100 km/h

A W

eigh

ting

Leve

l (dB

A)

Vehicle Speed (km/h)

Figure 14: Relationship between Noise and Speed

ROTOTEST NVH Model

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ROTOTEST Hub-Coupled Chassis Dynamometer

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GENERAL SPECIFICATIONSTorque uncertainty < 1% of measured valueSpeed uncertainty ：0.1 rpmRepeatability ： < 0.05%Inertia ： 0.6 kg�m2; 14.2 lb�ft2 (300 kW unit)：Maximum axle load： 3,500 kg; 7,716 lbsTemperature range： +15 to +40 C°; +59° to +104° F (except climate

model)Humidity ： 10-90%, non-condensingAltitude ： < 1,000 m; 3,000 ft above sea levelPower (SCU) ： 240 VAC (8A) or 120 VAC (16A) @ single phasePower (MPU) ： 400 VAC, 50 / 60 Hz @ 3 phaseCooling method ： Air Cooling

STANDARD MODELSystem ROTOTEST Energy 500-250 4WDComponent 1 axle of RE-500 (Dyno), 1 axle of RE-250 (Dyno),

MPU-500×2, MPU-250×2, SCU-4E×1Power† 2WD 500 kW/400 kW (momentary/continuous)Power† 4WD (50/50 split) 500 kW/400 kW ： (momentary/continuous)Torque ：2WD 6,000 Nm/2,550 Nm ： (momentary/continuous)Torque ：4WD (50/50 split) 5,960 Nm/2,450 Nm ： (momentary/continuous)Speed 2WD/4WD 2,700 rpm (maximum hub speed)Vehicle Speed 2WD/4WD ： 330 km/h (equivalent, wheel dia 650 mm)：

CLIMATE MODELSystem ROTOTEST Energy 230-CP 4WD Component 2 axles of RE-230-CP (Dyno), MPU-230CP x 4,

SCU-4E x 1Power† 2WD 230 kW/120 kW (momentary/continuous)Power† 4WD (50/50 split) 460 kW/240 kW (momentary/continuous)Torque ：2WD 2,800 Nm/1,200 Nm (momentary/continuous)Torque ：4WD (50/50 split) 5,600 Nm/2,400 Nm ： (momentary/continuous)Speed 2WD/4WD 2,500 rpm (maximum hub speed)Vehicle Speed 2WD/4WD ： 300 km/h; 205 mph (equivalent, wheel dia 650 mm)：Environment -31° to 105° F (-35° to 40° C) | 10-95% (humidity),

IP54 ：(non-condensing)

NVH MODELSystem ROTOTEST Energy 300-NVH 4WDComponent 2 axles of RE-300-NVH (Dyno), MPU-300 x 4,

SCU-4E x 1Power† 2WD 300 kW (5 min‡)：Power† 4WD (50/50 split) 600 kW (5 min‡)：Torque ：2WD 2,980 NmTorque ：4WD (50/50 split) 5,960 NmSpeed 2WD/4WD 3,000 rpm ： (maximum hub speed) ：Vehicle Speed 2WD/4WD ： 360 km/h; 224 mph ： (equivalent, wheel dia 650 mm)：Noise less than 45 dBA

SPECIFICATIONSEach system consists of dynamometers (2WD or 4WD), SCU, and MPU. The SCU is a system control unit, while MPU is the main power unit of each dynamometer.

† at 68° F (20° C)‡ defined as a 5 minute run / 30 minute cool down

© Copyright 2018-2019 TOYOTech. All rights reserved. All trademarks used in this document are the property of their respective owners. TOYOTech reserves the right to change product content and product specifications without prior notice. Contact your sales consultant for the latest information.

42840 Christy Street, Suite 110, Fremont, CA 94538Phone: 510-438-9548 | E-mail: info@toyotechus.com http://www.toyotechus.com

ABOUT ROTOTEST INTERNATIONAL ABFounded in January 1988, Rototest was established by a group of engineers with solid experience in product development in the vehicle industry. After a few years, devoted to intense development and testing, Rototest pioneered the market by introducing the world’s first hub-coupled dynamometer. The company is based in Sweden.

Rototest test solutions is today used by many of the world’s renowned industrial companies in more than 25 countries across North America, Europe, Asia and Africa.

ABOUT TOYO CORPORATIONTOYO is committed to providing the automobile industry with leading edge test and measurement solutions, and we maintain a fully staffed and functioning technical research lab in Atsugi, Japan.

The lab is equipped with the latest ROTOTEST Energy systems. The lab also serves as a demonstration facility where customers interested in the solution can see ROTOTEST test systems in operation. TOYO is a partner of Rototest.

04/15/2020 (SCW)