GKN Automotive creates a new test bed for EV drivetrain components

UK – GKN Automotive, the world leader in drive systems, has created a “real-time” test bed capable of handling the unique demands of electric vehicles to develop the most advanced, efficient and high-performance products in the world. market.

The rig, installed at GKN Automotive’s Offenbach site, can handle the extreme dynamics and higher torque of electrified powertrains, making conventional load test rigs unsuitable for the latest generation drivetrain parts, such as than the side shafts.

The “real-time capable” unit can test specific load data provided by customers, from small electric city cars to the most powerful SUVs, and is able to dynamically control speed and torque to replicate wheel slip and droop. other complex driving conditions. This sets new industry standards for accuracy and quality control in electric vehicle component testing and enables engineers to deliver the lightest and most efficient solutions without compromising capability.

With over 20 years of experience in electric vehicle drive systems, GKN Automotive has led the way in analyzing how best to design and engineer drivetrain products for electrified vehicles. It was early to identify that a new test regime would be needed to replicate the different load characteristics of electric motors compared to those of conventional combustion engines.

The state-of-the-art test rig is complemented by GKN Automotive’s high level of engineering expertise, which is crucial to properly configuring and running tests on the new rig. Data must be selected and validated by the team to establish test parameters, and the system must be carefully calibrated during setup to accurately replicate precise load dynamics.

By enabling the team to meet the most precise standards while minimizing the weight of components and the amount of materials used in their manufacture, the platform brings significant improvements in durability to GKN Automotive’s products and, by therefore, to its customers’ vehicles. This translates into improved efficiency and performance of electric vehicles, underscoring the importance of the platform in GKN Automotive’s mission to drive a cleaner, more sustainable world.

GKN Automotive already supplies eDrive systems to more than two million electrified vehicles worldwide, with core drivetrain components selected for use in drivetrain systems by a number of the world’s leading electric vehicle manufacturers.

Mario Syhre, Director of Product Technology at GKN Automotive, said: “Electric vehicles place different load dynamics on our drivetrain components and this new platform allows us to accurately replicate them to reach a level of testing without previous. Components need to be much stronger to cope with the higher torque and added weight of EVs, without significantly increasing their size or weight and remaining as cost effective as possible. The new platform allows us to accurately replicate the loads on our components, from small electric city cars to the most powerful SUVs, and deliver the lightest and most efficient solution.

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