Benches mechanics

Bench Mechanics


Dynamic vehicle testing system

The Powertrain Test Cell is an example of high-tech design. The solutions adopted in this system are highly innovative and define a clear-cut divide between the old approach to vehicle tests and the modern era of driveline testing.
Through the Powertrain Control System test cell it is possible to test the dynamics of 2WD and / or 4WD vehicles by carrying out driving cycles, like those performed in the well-known chassis-dyno test cells, but with better simulation dynamics. It is of course possible to carry out homologation cycles by interfacing the system with the various analysis systems (gas analyzer, CVS, …).
The bench is mainly composed of two or four electric motors depending on the type of application: 2WD or 4WD. The motors have the duty of absorbing the power supplied by the vehicle to the two / four outputs in correspondence of the driving wheels.


The vehicle is tested by means of two / four electric motors which, given the high reactivity, also allow the realization of dynamic tests (real dynamic stress conditions). The electric motors take care of absorbing the power supplied by the vehicle to the two / four outputs at the driving wheels. They are controlled by regenerative inverters, which exploit the energy dissipated by the motors, transforming it into electricity, which is fed into the plant network (a strategy that allows to drastically reduce energy consumption). The control of the electric motors is entrusted to the DBS (Dynamic Braking System) automation, produced by Control Sistem.

The 2WD vehicles can also be tested with a Powertrain 4WD Test Bench. In this case, the two excess electric motors can be handled in an extremely simply manner thanks to the air cushions which are installed below the support mechanism. So, if necessary, it is possible to levitate the group of interest on a thin layer of air: in this way, handling is made fast and easy.

One of the many qualities of Control Sistem's Powertrain test bench consists in being able to perform RLS simulations, moreover, thanks to the presence of a torque sensor at each wheel of the car, the bench can be used for R&D activities on traditional vehicles or hybrid or electric.

The automation and control software runs in the INT9000 environment developed by Control Sistem. It supervises and controls the standard peripherals connected (e.g. DBStr) and the micro PLCs that manage all the auxiliary circuits of the testing room.

The automation is also equipped with the Driver AID system, useful for performing emission cycles with a human driver on the car.

  • Ability to perform dynamic tests
  • Extremely reduced electrical consumption thanks to the use of regenerative inverters
  • Compatible with both 2WD and 4WD vehicles
  • Two / four independent electric motors, movable thanks to the use of air cushions
  • Intuitive software (INT9000 development environment)