Drive System Design expands electrified powertrain test facilities

EV powertrain engineering specialist Drive System Design (DSD) has announced a strategic expansion of its test facilities, adding two additional test cells for high-performance hybrids and EVs. 

The first of the new facilities can deliver input torque up to 2,500 Nm at 2,100 rpm, 525 kW at 7,000 rpm, and 350 kW at 1,100 V of battery emulation. The new test cells complement existing DSD facilities, which include a 450 kW highly transient ETPS machine (Engine Torque Pulse Simulator) and three battery emulators.

“The Covid-19 pandemic has put an ever-bigger spotlight on our environment and recent government announcements on ICE restrictions are resulting in a faster shift to electrified vehicles than first anticipated,” explained DSD Director David Kelly. “There is a significant increase in demand globally, not only for design and development work but also for outsourced testing. The additional facilities will extend our ability to provide this for a wide range of hybrid and electric powertrains.”

According to Kelly, even the largest, established vehicle manufacturers are struggling to accommodate the upsurge in test requirements using solely in-house facilities, and the situation is likely to become even more acute in the future. “We are in the middle of a sea change in the industry, as the major players allocate more of their manufacturing to EVs,” he says. “Companies like DSD can provide a vital additional resource to help satisfy short-term peaks in testing demand as this change in policy takes effect.”

DSD is continually developing its automation capabilities within the facility to help speed up testing. This has proven particularly effective in the case of hot and cold environment testing. According to Kelly, tests that previously took six weeks to complete can be finished in half the time with suitably configured automatic control.

Source: DSD