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E-Motor, Inverter, & E-Axle Dynamometer Testing

Electrified powertrains face demanding real-world duty cycles: rapid transients, regenerative operation, and sustained thermal loads. Rigorous dynamometer testing is essential to calibrate, validate performance, efficiency, durability, and control strategies before vehicle integration.
At DEKRA, we provide powertrain dynamometer testing for e-motors, inverters, and integrated e-axles. Our laboratory combines bidirectional battery simulation, high-speed and high-torque dynamometers, precise thermal control, and synchronized data acquisition to deliver objective, repeatable results for engineering and quality teams.

What Is Dynamometer Testing for Electrified Powertrains?

Dynamometer (dyno) testing couples a Device Under Test (DUT) to controlled absorber/motoring machines and a programmable DC source that emulates the vehicle battery. We execute steady-state and transient profiles across the speed × torque operating range—including traction and regenerative quadrants—to quantify efficiency, losses, thermal behavior, torque accuracy/latency, and limits.

Why Is This Testing Important?

  • Calibration: Testing to ensure quality of the control strategy and software.
  • Performance & Efficiency: Generate validated efficiency and loss maps for accurate vehicle modeling.
  • Controls & Safety: Verify torque fidelity, response, and protection behaviors under realistic electrical/thermal constraints.
  • Thermal Robustness: Establish continuous/30-minute power and derating curves with coolant/oil set-points representative of the vehicle.
  • Durability & NVH (e-axle): Assess long-cycle loads and acoustic characteristics to reduce in-vehicle surprises.
  • Cost & Risk Reduction: Catch issues earlier, shorten iterations, and de-risk program milestones with traceable data.

DEKRA’s Dynamometer Testing Capabilities

We operate a modern powertrain test cell with configurable hardware and controls to support diverse DUTs and requirements:
  • Battery Simulation (bidirectional): up to 1,200 V / 1,000 A / 500 kW
  • Dynamometers:
    • Input dyno (1): up to 450 kW, 26,000 rpm
    • Output dynos (2): up to 460 kW each, high-torque to ~5,000 Nm (Nominal), ~3,000 rpm; 6,000 Nm overload for 30 seconds.
  • Power & Torque Measurement: Multi-channel HV DC + 3-phase AC power analysis (e.g., WT-class), in-shaft torque/speed (multiple meters).
  • Data Acquisition & Control: Real-time dyno control, CAN/CAN-FD access, high-rate logging with precise time synchronization
  • Typical Programs:
    • Speed×torque efficiency & loss mapping (traction & regen)
    • Controls & transients (torque steps, tip-in/out, field-weakening)
    • Thermal characterization (continuous & 30 - second power; derating curves)

Standards and Compliance

Testing can be performed in accordance with commonly referenced specifications, as applicable to the DUT and test objective,
DEKRA can also work to unique customer test plans and data packages.

Contact DEKRA

Powertrain dyno testing is a practical way to confirm performance, efficiency, and thermal behavior before vehicle integration. Contact DEKRA to discuss your DUT, test matrix, and deliverables. We provide calibrated, time-synchronized data and clear reporting to support engineering decisions and program gates