In addition to 12 test benches for drive machines with 4-quadrant operation, the IFA has a state-of-the-art hardware-in-the-loop (HiL) test bench, test benches for e-drives (including fuel cells) as well as a 4-wheel chassis dyno and several component test benches and 4 -CFR test engines.
Engine test benches
The engine test benches are all equipped with modern, partly self-developed, measuring and control systems, which allow a very flexible response to the needs of the respective project. Optionally, test benches can also be air-conditioned down to a temperature of -28 °C. All test benches are equipped with highly dynamic dynos, e.g. to realize cycles including thrust phases directly at the test bench. Furthermore, dynos are realized as HiL test benches. The engine test benches are designed for a wide range of power and torque levels up to 500 kW and 3000 Nm.
In order to be able to operate and test e-drive systems – be it batteries, fuel cells or e-machines – the IFA has several battery simulators. The most powerful battery simulator enables the delivery of a continuous output power of up to 250 kW at a voltage of up to 1200 V.
Fuel cell test bench
At the transient fuel cell test bench the effects of adjustable operating parameters can be analyzed by means of a self-developed software. Furthermore, the fuel cell system is coupled in-the-loop with a vehicle model, whereby cycles can be retraced and operating strategies can be developed. In addition to this parameterizable fuel cell in-the-loop test bench, off-the-shelf fuel cell systems can also be tested at the IFA.
4-wheel chassis dynamometer
The TU Wien Automotive Test Center GmbH acts as a link between the TU Wien and industry in terms of research and development in all matters relating to exhaust-emissions and powertrain testing.
The services offered at the modern 4-wheel chassis dynamometer include the determination of the legally limited exhaust emissions (Euro 6d-compliant), support of the vehicle development process (including map calibration, performance measurements), investigation of alternative powertrain concepts, benchmarking and laboratory of EU / Green Vehicle Index and FIA / Green NCAP.
In particular, there is the possibility to measure electric vehicles and also to charge the traction battery with the 300kW Hypercharger in the test cell.
4 CFR test engines
The four CFR test engines owned by the institute enable the MON determination according to ASTM D2700 (EN ISO 5163) and the RON determination according to ASTM D2699 (EN ISO 5164) for gasoline fuels, the cetane number determination for diesel fuels according to ASTM D613 (EN ISO 5165) and the octane number determination for alcohol and alcohol blended fuels according to DIN 51756 T. 7.
- Gasoline fuels: MON determination according to ASTM D2700 (EN ISO 5163);RON determination according to ASTM D2699 (EN ISO 5164)
- Diesel fuels: CN determination according to ASTM D613 (EN ISO 5165)
- Alcohols/mixed alcohol fuels: Octane number determination according to DIN 51756 T. 7
Component test benches
Research projects often focus not only on the engine as a whole, but also on individual engine or other powertrain components such as transmissions, battery cells or electric machine components. In order to be able to evaluate these components as well, the IFA not only has specific component test benches (transmission test bench, battery cell aging test bench depending on the ambient and operating conditions), but also, for example, a flow bench for measuring various flow coefficients for internal combustion engines.
In-house component and prototype production
In the own workshop at the IFA, many components for the test bench operation can be manufactured and machined in-house. The development and production of own prototypes for various projects can also be realized. This allows a very high flexibility in project handling.