C O N T R O L

Sistem

Control

Performance analysis of vehicle powertrains

The Powertrain Test Bench is a product entirely designed and built by Control Sistem and through which it is possible to test the dynamics of 2WD and/or 4WD vehicles by carrying out driving cycles, guaranteeing results with the same precision that can be obtained in a chassis-dyno test bench, but with better simulation dynamics. It is therefore also possible to perform homologation cycles, by interfacing the system with the various necessary analysers.

Thanks to a Powertrain Bench it is also possible to test the single powertrain without the need to install the entire vehicle in the test cell.

The powertrains that can be tested on Control Sistem test benches can be classic (endothermic engines), full electric or hybrid. The powertrain unit tested can be both transverse and longitudinal (gearbox + differential), both manual and automatic.

Depending on the case, the test bench is therefore mainly composed of two, three or five electric motors. In case of 2WD transmission testing, two electric motors are in charge of simulating vehicular inertia, while the third is responsible for simulating the vehicle internal combustion engine. Similarly, in the case of testing a 4WD transmission, there are four electric motors in charge of simulating vehicular inertia, while the fifth eventually deals with the simulation of the combustion engine.

Features

  • Dynamometric brakes: the right coupling between the electric motors (or dynamos) and the drive panel guarantees high regulation accuracy and therefore allows an accurate evaluation of the performance of the transmission in all conditions.
  • Transmission chain: to ensure the necessary mechanical connection between each motor brake and the powertrain under test, Control Sistem designs and assembles a telescopic transmission chain for each motor of the test bench. The transmission chains are also equipped with a torque flange for each of them, with a customizable scale and able to communicate with the automation system either in analog or in EtherCAT, if necessary.
  • Electric motor handling system: in order to adapt the test bench to the powertrain under test, the motor units can be easily moved by means of a lifting system that uses the factory's compressed air and anchored to the floor by means of electromagnets.
  • Measurement instrumentation: the test benches are equipped with sensors useful for ensuring both good regulation (such as encoders, torque transducers, etc.) and measurement and evaluation of the performance tested on the bench.
  • Automation system: powertrain test bench automation systems simplify and optimize the testing process for maximum operational efficiency. In addition, I allow the operator to carry out the various phases of preparation and testing of the transmission in a simple, automatic and intuitive way.
  • Automatic gear change systems: in case of installation of an entire vehicle in the test cell or a transmission with manual transmission, it is necessary to equip the test bench with a system capable of automatically varying the gear to be engaged. This system consists of an anthropomorphic robot which can act on the gear lever and an actuator acting on the transmission clutch.
  • Test Cells: in addition to the test benches, Control Sistem is able to design and build the cell that house the test bench themselves. As a General Contractor, many Control System projects start from the ground or floor and go all the way to the realization of a turnkey project.

Products

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Why Choose Control Sistem

  • Engineering: test benches are specifically engineered and designed for the requirements of the vehicles or motorbikes to be tested.
  • Customising: for Control Sistem there are no real standard catalogue products, but any solution can be engineered to meet customer specifications.
  • Precision: every component is carefully designed to ensure precision and reliability.
  • Experience: thanks to a long history in the automotive industry, Control Sistem expertise is a guarantee for the provision of a safe and reliable system.

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