Transmission Calibration / Testing

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FWD Test Bench

General

The powertrain test stands developed and operated by GIF precisely reproduce the vehicle and the vehicle tests allowing powertrain tests way before the prototypes become available. The main advantage of the test bench operation is the time saving aspect due to optimisation of the test sequence and 24 hour test bench operation on 7 days a week.

A further advantage is the cost reduction due to easy assembly and disassembly of the test specimens as well as easy accessibility for measuring equipment adaptations.

FWD Test Bench with GSE2 and KBE

Technical Description

All test benches are suitable for the application of combustion engines as transmission power unit. GIF has developed torsion resistant test bench racks to which the complete powertrain can be attached by the specified suspension points enabling immediate operation. The vehicle mass can either be completely simulated by the mechanical flywheel mass, electrically or in combination of mechanical mass and electrical simulation. Highly dynamic electrical 4 quadrant-E-machines are applied to simulate the driving resistance and driving force.

To test manual shift transmissions the GIF Shift Robot GSE2 together with the Clutch Actuation Unit KBE can be applied. Electrical positioning units are used to actuate the selector lever of automatic transmissions. Automated manual transmissions as well as twin-clutch transmissions can be shifted directly through the CAN-Bus.

4WD Test Bench

The PC programme system PDES is our automation system. Besides the realisation of various process controls, PDES also enables to retrace the data measured in the vehicle. A Fuzzy Logic driving model can also simulate real driving characteristics. A second PC system is used for highly dynamic data acquisition (e.g. structure borne noise measurements with online frequency analysis for early detection of damage). The test spectrum reaches from durability tests, functional tests, efficiency and low temperature tests up to road load simulations.

4WD test bench with mechanical momentum wheels

Technical Data of our Test Benches

At our locations we have the following cumulated test benches

	No of Test Benches
5 E-Machines	1
4 E-Machines	3
3 E-Machines	17
2 E-Machines	24
1 E-Machines	3