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Institute of Vehicle System Technology
KIT – University of the State of Baden-Wuerttemberg and National Research Center of the Helmholtz Association www.kit.edu
Testing Facilities Institute of Vehicle System Technology – FAST Karlsruhe, September 2018
Institute of Vehicle System Technology 2 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Contents Institute of Vehicle System Technology
Structure Facilities of FAST
Flat Track / External Drum Test Bench Technical Data Rolling Resistance Measurements
Internal Drum Test Bench Technical Data Overview of Measurements & Tracks Longitudinal Force Measurements Measurements on Wet Track Surface Measurements on Snow and Ice Surfaces Measurements with the TIME Procedure Measurements for Tire Comfort Models Determination of the Magic Formula Coefficients Equipment for Determination of Tire Envelopes Setup for Acoustic Test Tire contact force sensor
Grip- and Abrasion Test stand (GAT) Facilities of FAST at Campus Ost
Buildings 70.21 & 70.22 Vehicle-In-the-Loop Test Rig (VEL) in Building 70.21 Acoustic 4WD Chassis Dynamometer Noise, Vibration and Harshness Tests
Test vehicles Contact
Flat Track / External Drum
Internal Drum Test Bench
Acoustic 4WD Chassis Dynamometer
Vehicle-In-the-Loop Test Rig
Institute of Vehicle System Technology 3 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Institute of Vehicle System Technology - FAST Structure
Rail Vehicle Systems BST Prof. Dr.-Ing. Peter Gratzfeld
Drivability
Passenger Cars & Trucks LFF Prof. Dr. rer.nat. Frank Gauterin
Energy Efficiency
Safety
Mobile Machines MOBIMA Prof. Dr.-Ing. Marcus Geimer
Vehicle System Technology
Cost
Light Weight Technology LB Prof. Dr.-Ing. Frank Henning
Chair of Vehicle Technology
Institute of Vehicle System Technology 4 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST Campus Süd – Campus Ost
Institute of Vehicle System Technology 5 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Flat Track / External Drum Test Bench Technical Data
Measurement of Rolling Resistance
Outside diameter of the drums 2,00 m 1,71 m Top speed - on the drums 300 km/h - on the flat surface 250 km/h Camber angle -10°...+10°
Slip angle -5° ... +5°
Measuring system for rolling resistance
6 component measuring system:
Max. vertical force 10.000 N
Max. lateral force, longitudinal force 1.000 N
Max. overturning torque 1.200 Nm
Max. aligning torque 300 Nm
Max. driving torque 30 Nm
Institute of Vehicle System Technology 6 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
0
10
20
30
40
50
60Um
fang
skra
ft / N
0 10 20 30 40 50 60 70 80 90Zeit / min
Reifen-Nr.Reifengröße LuftdruckRadlastUmgebungstemp.
: 1: 195/65 R 15: 2,9 bar: 80 % ETRTO: 25 °C
Flat Track / External Drum Test Bench Rolling Resistance Measurements Measurement of rolling resistance versus time, variation of velocity
Lo
ngitu
dina
l For
ce /
N
Time/ Minutes
50 km/h 90 km/h 120 km/h 150 km/h 180 km/h
Institute of Vehicle System Technology 7 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
0
10
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90
100
Long
itudi
nal f
orce
/ N
20 40 60 80 100 120 140 160 180Velocity / km/h
1,71 m drum2,0 m drumFlat trackAerodynamic Resistance
Tire No.Tire Size TrackInfl. Pressure
: 5: 225/45 R 17: 1,71 m, 2,0 m, Flat: 2,2 bar
Influence of driving velocity on the rolling resistance for different track surface curvatures.
Measurement of rolling resistance on different curved track surfaces on a combined flat track external drum test bench.
Flat Track / External Drum Test Bench Rolling Resistance Measurements
100 % ETRTO
80 % ETRTO
40 % ETRTO
Tire load
Institute of Vehicle System Technology 8 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Technical Data
Inside diameter of the drum 3,80 m Track surfaces Safety Walk Diverse concrete surfaces Diverse asphalt surfaces Top speed - on Safety Walk 200 km/h - on asphalt / concrete 150 km/h Water film depth 0 ... 4 mm Ambient temperature -20 ... +30 °C Slip angle -20° ... +20° Camber angle -10° ... +20° (+30° ... +45°)
Max. Tyre Radius: 480 mm Max. Tyre Width (Contact-Width): 330 (270) mm
Measuring system for frictional force behaviour:
Rotating 6 component measuring system: Max. vertical force, lateral force, longitudinal force 15 kN Max. driving torque, overturning torque 5.500 Nm Max. aligning torque 1.500 Nm
Institute of Vehicle System Technology 9 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Overview of Measurements
Test Methods − Longitudinal force versus slip − Lateral force and aligning moment versus slip
angle − TIME procedure − tire comfort measurements (rolling over cleats)
Variation of ambient conditions − Different track surfaces (safety walk, asphalt,
concrete) − Dry, wet, snow and ice surfaces − Variation of ambient temperature − Different types of cleats
Institute of Vehicle System Technology 10 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Installable Tracks
SRT 39SRT 44SRT 51SRT 53
Reifen:Geschwindigkeit:Radlast:Wasserhöhe:Profiltiefe:
Sommerreifen B80 km/h4000 N0,1 mm2 mm
Schlupf [ % ]
Umfa
ngsk
raft
[ kN
]
-40 -30 -20 -10 0 10 20 30 40
-4
-3
-2
-1
0
1
2
3
4
5
-5
Analysis of the influence of • different composites of the track • different textures of track surface
for example: • Safety-Walk • asphalt • concrete
on the frictional behavior of tires on wet and dry roadway.
Variation of skid resistance, tests on humid track surface
Institute of Vehicle System Technology 11 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Longitudinal Force Measurements
-8000
-7000
-6000
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Long
itudi
nal f
orce
/ N
-110-100-90-80-70-60-50-40-30-20-10010
Longitudinal slip / %
250 N1500 N3000 N4000 N4800 N
: 100 km/h: 2,1 bar: 0°: 0 mm: var.
: :: 5,5 x 15
ManufacturerTyre sizeRim size
VelocityInflation pressureSlip angleWaterfilm depthVertical force
-8000
-7000
-6000
-5000
-4000
-3000
-2000
-1000
0
1000La
tera
l for
ce /
N-8000 -6000 -4000 -2000 0 2000 4000 6000 8000
Longitudinal force / N
0 °2 °4 °
Slip Angle:
ManufacturerTyre sizeRim size
VelocityInflation pressureCamber angleWaterfilm depthVertical force
: 40 km/h: 2,2 bar: 0°: 0 mm: 4800 N
: :: 7,5 x 16
Institute of Vehicle System Technology 12 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements on Wet Track Surface
-6000
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-1000
0
1000
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Long
itudi
nal f
orce
/ N
3020100-10-20-30Longitudinal slip / %
6000 N, waterfilm depth: 0 mm6000 N, waterfilm depth: 0.2 mm6000 N, waterfilm depth: 2 mm
ManufacturerTyre sizeRim size
VelocityInflation pressureSlip angleWaterfilm depthVertical force
: : : 6,0 x 15
: 80 km/h: 2,6 bar: 0°: 0 / 0.2 / 2 mm: var.
Vertical force:
Institute of Vehicle System Technology 13 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements on Snow and Ice Surfaces
Institute of Vehicle System Technology 14 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements on Snow and Ice Surfaces
Lateral traction determined in 2 cycles by varying the slip angle.
α±
Test Procedures - Lateral Traction on Snow
Institute of Vehicle System Technology 15 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
s = -5 ... 50%
Longitudinal traction performance is determined within one drum turn to avoid rolling over of iced surfaces.
Internal Drum Test Bench Measurements on Snow and Ice Surfaces
Test Procedures - Longitudinal Traction on Hard Packed Snow
Institute of Vehicle System Technology 16 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
On tracks with low hardness, high traction forces can be transmitted under high slip.
Medium packed snow CTI 82
Ice
Hard packed snow CTI 90
Distinctive force maximum on hard packed snow and ice.
Internal Drum Test Bench Measurements on Snow and Ice Surfaces
Influence of Track Hardness on Winter Roads
Institute of Vehicle System Technology 17 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements on Snow and Ice Surfaces
-3000
-2500
-2000
-1500
-1000
-500
0
500
1000
1500
Long
itudi
nal f
orce
/ N
-100-90-80-70-60-50-40-30-20-10010Longitudinal slip / %
1500 N 3000 N 4500 N 6000 N 7800 N
ManufacturerTyre sizeRim sizeInflation pressure
VelocitySlip angleTrack surfaceAmbient temperatureVertical force
: 80 km/h: 0°: Ice: -10 °C: variabel
::: 6,5 x 15: 2,4 bar
-2000
-1500
-1000
-500
0
500La
tera
l for
ce [
N]-100 -80 -60 -40 -20 0 20 40 60 80 100
Longitudinal slip [ % ]
0° 2° 4°
ManufacturerTyre sizeRim sizeInflation pressure
: : : 6,5 x 15: 2,4 bar
VelocitySlip angleTrack surfaceAmbient temperatureVertical force
: 80 km/h: variabel: ice: -10 °C: 6000 N
Slip angle
Institute of Vehicle System Technology 18 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements with the TIME Procedure
-10
-5
0
5
10
Slip
ang
le /
°
0 50 100 150 200 250Measurement point / -
Measurement Target value
: : : : 7 x 16
: 40 km/h: 2,4 bar: var.: 0 mm: var.
ManufacturerIdentityTyre sizeRim size
VelocityInflation pressureInclination angleWaterfilm depthVertical force
-8000
-7000
-6000
-5000
-4000
-3000
-2000
-1000
0
1000
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6000
7000
8000
Late
ral f
orce
/ N
0 50 100 150 200 250 300Measurement point/ -
ManufacturerIdentityTyre sizeRim size
VelocityInflation pressureInclination angleWaterfilm depthVertical force
::: : 7 x 16
: 40 km/h: 2,4 bar: var.: 0 mm: var.
H-Axis-System
Adjustment of certain parameter combinations (constant for 3 sec)
Measurement of tire forces at adjusted parameter combinations
Institute of Vehicle System Technology 19 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements for Tire Comfort Models Rolling over Cleats
Changeable Pavement and changeable cleats
Institute of Vehicle System Technology 20 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Internal Drum Test Bench Measurements for Tire Comfort Models
-202468
101214
Mz [N
m]
-600
-400
-200
0
200
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600
Mx [N
m]
0
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4000
6000
8000
F z [N]
-400
-200
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F y [N]
-2000
-1000
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F x [N]
0.00
0.02
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²m²s
]
Powe
r spe
ctru
m
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²m²s
]
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r spe
ctru
m
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]
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r spe
ctru
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]
Powe
r spe
ctru
m
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F x [N²s
]
Powe
r spe
ctru
m
0.00 0.05 0.10 0.15 0.20Time [s]
0 20 40 60 80 100 120 140 160 180 200Frequenz [Hz]
ManufacturerTyre size Form of cleat
Vertical forceVelocityInflation pressureSlip angle
: 4.000 N: 100 km/h: 2.2 bar: 0°
: : : Batten
Measurement of Forces and Moments
Institute of Vehicle System Technology 21 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Inner Drum Test Rig Determination of the Magic Formula Coefficients
Lateral force versus slip angle Longitudinal force versus longitudinal slip
Institute of Vehicle System Technology 22 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Inner Drum Test Rig Equipment for Determination of Tire Envelopes
Measurement under Real Driving Conditions at Internal Drum Test Bench
Institute of Vehicle System Technology 23 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Inner Drum Test Rig Equipment for Determination of Tire Envelopes
15kN measuring hub
balance weight
tire
wheel suspension
cameras and laser for tread
gear wheel
stepper motor
camera and laser for sidewall/
mirror
Institute of Vehicle System Technology 24 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Inner Drum Test Rig Equipment for Determination of Tire Envelopes
Light Section Triangulation Method
detector / camera
device under test
laser
profile contour
known
b α β
x
Institute of Vehicle System Technology 25 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Measurement under Real Driving Conditions at Internal Drum Test Bench
Non-contact measurement of tire contour under real (even extreme) driving conditions on real track surfaces
with measurement of tire forces and moments at the same time.
Inner Drum Test Rig Equipment for Determination of Tire Envelopes
Measured tire contour for several load and slip angle conditions
Institute of Vehicle System Technology 26 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Inner Drum Test Rig Setup for Acoustic Test
1. Drive shaft is decoupled mechanically by elastic flexible disc. 2. Acoustic dividing wall: Subdivision of the test rig into a
measuring cabin and a cabin for the power unit. 3. Solid-borne sound reduction: wheelhouse with the hydraulic
motor is placed onto dampening mounting feet 4. Applying the wheel force through an electrically driven ball
screw 5. Absorption modules ensuring a semi-anechoic space
1
3
3 2
0 1000 2000 3000 4000 5000
Frequency [Hz]
0
5
10
15
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25
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35
40
Soun
d R
educ
tion
[dB
]
sound reduction index
Result: Reduced sound generation caused by the
power unit.
Institute of Vehicle System Technology 27 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Inner Drum Test Rig Analysis of Tires Contact Forces with Triaxial Force Sensor
Triaxial Force Sensor
Telemetry
Top View
Contact
Institute of Vehicle System Technology 28 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Visualization of the tire tread deformation
mobile under-floor laboratory installed into a common drain on the
street
mobile under-floor laboratory
illumination with > 14.000 Lumen recording of tire crossing > 2,300
fps
easy integration simple handling
[2] DE102013107018.3 [2] DE102013107018.3
Institute of Vehicle System Technology 29 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Visualization of the tire tread deformation
start-up carpet avoids collecting stones and dust particles by the tire during drive up light barrier (a) activates pre-defined torque at electric vehicle automatically reproducible tangential forces can be applied light barrier (b) activates camera recording
mobile under-floor laboratory
fully automated
a
b
Institute of Vehicle System Technology 30 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Grip- and Abrasion Test stand (GAT)
loading unit
watering unit
drive unit
water supply
water drain
Institute of Vehicle System Technology 31 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Grip- and Abrasion Test stand (GAT)
pneumatic cylinder
shock absorber
load cell
rubber sample fixation
surface sample cast watering unit
Institute of Vehicle System Technology 32 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Grip- and Abrasion Test stand (GAT)
sliding body
rubber wheel
Institute of Vehicle System Technology 33 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST at Campus Ost Buildings 70.21 & 70.22
Assembly area passenger cars
Vehicle-In-the-Loop Test Rig
Acoustic 4WD Chassis Dynamometer
Vibration Test Room
Mechanical Workshop Exterior Front View
70.22
70.21
Institute of Vehicle System Technology 34 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST at Campus Ost Building 70.21
Truck lift
Assembly area passenger cars
Exterior view Building 70.21
Institute of Vehicle System Technology 35 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Main applications: • Direct, dynamic street load simulation with robots (pedals and steering wheel) for power & consumption measurement,
• Powertrain characteristic at certain speeds, • Influence of tires force characteristic, …
Facilities of FAST at Campus Ost Vehicle-In-the-Loop Test Rig (VEL) Vehicle-In-the-Loop Test Rig Technical Data:
Max. vehicle mass: 12,000 kg
Max. wheel load: 3,000 kg
Wheel base: 1.8 – 4.9 m
Track width: 1.2 – 3.9 m
Max. Speed (1) 2.000 min-1 (200...260 km/h)
Max. Torque (1) 2.500 Nm Power (1) 209 kW Max. Slip angle front (2) +/- 20° Max. Aligning Torque (2) 1.000 Nm Max. wind speed (4) 135 km/h Room temperature 18 ... 65°C
Vehicles wheel hubs directly connected to the dynamic operating load engines. Torques are measured close to wheel (3).
1 2
5
4
3
Institute of Vehicle System Technology 36 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST at Campus Ost Acoustic 4WD Chassis Dynamometer (AARP)
Cross Section of Test rig implemented in Building 70.22 (Source: Dömges Architekten, Dreher)
Max. vehicle mass: 56,000 kg
Max. wheel load: 14,000 kg
Wheel base: 1.8 – 4.9 m
Track width (rollers inner & outer edges): 0.85 – 3.55 m
Max. Vehicle Dimensions: 18 m x 4 m x 4,5 m (LxWxH)
Nom. I max. traction force: 240 kN I 440 kN
Max. air flow rate 180.000 m³/h @ 3 m x 3 m
Max. speed 160 km/h
Acoustic insulation hemi-anechoic room (ISO 3745)
Simulator for sun and heat influence.
Institute of Vehicle System Technology 37 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST at Campus Ost Test Setup for Analysis of Acclimatization at AARP
Pos. Specification Value
1 Temperature Range +20°C to +50°C
2 Speed of air: 1,5 m/s bis 49,5 m/s
3 Size of area for air intake of condenser / motor cooler: 1,2 m x 0,8 m
4 Size of area for air intake of vehicle acclimatization system: 0,5 m x 0,1 m
4 Humidity of air for acclimatization system: max. 68 kg/h
5 Radiation power of solar simulators (6x, each 2000 W, HQI) 370 W/m2 bis 1050 W/m2
5 Size of area, which can be radiated by solar simulators: 2,5 m x 1,0 m
6 Radiation power of infrared radiators (12x, each 2000 W): 148 W/m2 bis 1100 W/m2
6 Size of area, which can be radiated by infrared radiators: 2,5 m x 2,3 m
1
2
3
4
5
6
Institute of Vehicle System Technology 38 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST at Campus Ost Climate chamber for small vehicles
Specification Value
Temperature -25°C to +25°C
Inner dimensions (L*W*H) 5,48m*2,28m*2,25m
Max. Vehicle dimensions (L*W*H) 3,80m*2,00m*1,65m
Institute of Vehicle System Technology 39 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Facilities of FAST Noise, Vibration & Harshness Tests
Tire noise Car noise
Tire vibration Car vibration
Analysis of 1. Seismic mass (300t) 2. Shaker 3. Power cable 4. Sensor 5. Adapter 6. Acoustic torus
measurement device
Institute of Vehicle System Technology 40 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Noise Generation : Pass-By Measurements
Experimental Setup
a: light barrier activates pre-defined torque automatically reproducible tangential forces can be applied b: experimental tire @ right front; slick tires @ left side
c: microphone & artificial head: 4m distance, 1.2m height
d: very dense surface, no ISO-surface
a
b
c
d
Institute of Vehicle System Technology 41 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Noise & Vibration analyzed with Elastic Wheel Hub
Noise and vibrations measured by multiple triaxial accelerator sensors, microphones and 3D-Scanningvibrometer (see complete list next slide).
Institute of Vehicle System Technology 42 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST NVH – Equipment
Amount Type Brand 6 Freefield and Diffuse Microphone 1/2‘‘ B&K 12 Freefield Microphone 1/4‘‘ G.R.A.S. 4 Microphone – pressure type bis 180dB PCB 1 Acoustic Head Measurement System Head Acoustics 16 Triaxial Accelerometer B&K 1 3D-Scanningvibrometer Polytec
No. of input channels
Performance Brand
96 fMess 25,6 kHz; 16bit B&K Pulse 24 fMess 51,2 kHz; 24bit; ICP NI PXI 8 (drahtlos) fMess 25,6 kHz; 24bit; ICP NI WLS
Sensors
Data Acquisition
Institute of Vehicle System Technology 43 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Test Vehicles
• smart fortwo cdi • Mercedes-Benz C 200 cdi • Mercedes-Benz E 220d • Mercedes-Benz S 500 as Acoustic Test Vehicle • Mercedes-Benz A-Class converted to a ”Battery Electric Vehicle” • Mercedes-Benz Atego 815 • Mercedes-Benz Actros 1845 LS 4x2
Institute of Vehicle System Technology 44 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Test Vehicles: Battery Electric Vehicle
Technical and calculated* data Nominal power (max.) 45 kW (65 kW)
Operating distance* (NEFZ) 150 km (90% SOC)
Max. speed* 154 km/h
Charging time 10 h
Type of battery LiFeMgPO4
Number of modules (of cells)
21 (50p x 6s = 300)
Capacity 27,8 kWh
Battery nom. power (Max.) 48,4 kW (80,6 kW)
Institute of Vehicle System Technology 45 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Test Vehicles: Battery Electric Vehicle
Institute of Vehicle System Technology 46 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Test Equipment of FAST Test Vehicles: Battery Electric Vehicle
Modeling and Simulation
Model of electric powertrain Simulation of battery electric drive
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Torq
ue / N
mC
urre
nt / A
Velo
city
/ m
/s
Time / s
Load profile during regenerative braking
speedcurrentTorque
Development of vehicle control software e.g.: software sequence for regenerative braking
Hardware modification for regenerative braking
Institute of Vehicle System Technology 47 Testing Facilities of the Institute of Vehicle System Technology, September 2018.
Contact
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