Powertrain Systems

Our test benches are optimized for all components and configurations—from individual inverters to complete systems, from high-voltage heaters to high-performance e-drive systems.

Range of services and technical specifications

• Test case creation and test management
• Automated, cloud-based data analysis
• Complete coverage of all tests in accordance with the following standards: ISO 21498-2, VW80300, MBN11123, LV123, and comparable standards—without exceptions (also available as ISO 17025-compliant measurement)
• Freely configurable measuring equipment; no project-specific preparations are required on the customer’s side
• Ripple voltage up to 1,200 Vpp
• All tests are possible up to 1,000 V / 1,000 kW

The Pack-2-Pack test bench enables efficient testing of high-voltage (HV) batteries. Our focus is on functional and endurance testing:

• Testing of up to 10 test specimens—HV vehicle batteries or battery modules
• Dimensions: max. 280 x 180 x 60 cm (L x W x H), Weight: max. 700 kg
• Power limitation to max. 1,000 A / 900 V / 900 kW
• Any cell chemistries = lithium-ion / solid-state batteries / lithium iron phosphate (LFP)
• Safety classification: max. Hazard Level 3

In our state-of-the-art Materials Science Lab, we conduct basic research and product development using analytical and simulation-based methods.

• Disassembly of target cells and physicochemical analyses
• Macroscopic structure (geometry, edge regions, etc.)
• Microscopic structure (number of layers, overhangs, etc.)
• Composition (anode, cathode, separator, electrolyte, etc.)
• Layer thicknesses, porosities
• Thermal properties

Using the Road to Rig method, we test HV components individually and as part of an integrated system during early development phases:

• Complete 4WD BEV powertrains
• Integration of components via simulation or existing hardware (e.g., drive battery)
• Up to 13 HV subcomponents that can be switched individually

Test bench technical specifications

• Speed 3,300 rpm
• Torque 2,300 Nm (peak 4,150)
• Braking power 280 kW (peak 500)

Battery conditioning unit

• Temperature range -70 to 150 °C
• Max. battery dimensions 400 x 220 x 200 cm (WxDxH)

Technical specifications of the battery simulator

• Electrical power 500 (+500) kW
• Current 2,000 A
• Voltage 1,000 V

IAV has state-of-the-art fuel cell test benches on which complete systems and subcomponents are tested under realistic load profiles. This enables us to lay the groundwork for reliably ensuring efficient and robust fuel cell powertrains for future applications.

• Fuel cell stack: max. 180 kW
• Fuel cell system: max. 150 kW
• Voltage: max. 1,000 V
• Current: max. 1,000 A
• Cooling capacity: max. 250 kW

IAV operates engine test benches for passenger car and heavy-duty engines with an integrated hydrogen supply of up to 80 bar. This enables us to lay the groundwork for the safe and efficient development of conventional and alternative powertrains as we move toward a low-emission future.

Conventional Powertrains

• Power: max. 1,500 kW
• Torque: max. 7,500 Nm

Hydrogen

• Power: max. 1,500 kW
• Torque: max. 7,500 Nm

The altitude climate roller dynamometer efficiently simulates high-altitude driving up to 5,300 meters. Test bench automation and simulation enable cost-effective and reproducible test runs.

• Altitude simulation up to 5,300 m (500 mbar absolute)
• Temperature simulation from -30°C to +40°C
• 230 kW axle power at -20°C
• Humidity control up to an altitude of 1,800 m

As a DAkkS-accredited testing laboratory, IAV meets all qualitative and quantitative requirements for mobile, automotive-specific measurement technology. This enables us to guarantee reproducible results of the highest quality and provide a solid foundation for well-informed development and validation decisions.

• Test equipment control
• Calibration in accordance with ISO 9001 and ISO 17025
• Metrology consulting