Testing and validation

In the research group for testing and validation, components and systems for new drive technologies are evaluated using cutting-edge test and measurement equipment. The objectives of the tests are to characterize and evaluate the components and systems in terms of their functionality, efficiency, emissions and service life.

Multiple test stands are available in the testing and validation group to evaluate novel, CO2-neutral drive technologies and systems. These range from systems to acquire real-world driving data, and the testing of electric motors and hydrogen combustion engines, through to the highly flexible component and system test stands used, for example, to test the air supply components of fuel cell systems. If a new test stand is necessary, it is developed and constructed in collaboration with the design and simulation groups.

Connecting the test stands enables an efficient and holistic development process for modern drive technologies.

Electric motor test stand

Electric motor test stand with swiveling device for continuous power up to 300 kW, in cooperation with SciMo - Elektrische Hochleistungsantriebe GmbH
© Fraunhofer ICT
Electric motor test stand with swiveling device for continuous power up to 300 kW, in cooperation with SciMo - Elektrische Hochleistungsantriebe GmbH

As part of the Fraunhofer lighthouse project Albacopter, a swivel test rig for electric motors was developed and put into operation in 2023. The focus is on realistic testing, for example of aeronautical flight propulsion systems whose cooling and lubrication systems are exposed to considerable acceleration during operation due to rapid changes in direction. Fraunhofer ICT’s test stand will enable the early validation of flight propulsion systems in terms of function and service life. Current projects for testing electric motors are carried out in cooperation with other institutions.

Vehicle simulation

Vehicle simulation platform
Vehicle simulation platform

Any vehicle and powertrain topology can be mapped within the vehicle simulation model developed at Fraunhofer ICT. In the creation of digital twins, the focus is on detailed modeling of the drive components and their thermal conditioning, and on subsequent system and component optimizations to increase efficiency and/or reduce (driving) energy demands. In our vehicle simulation platform, all powertrain components are represented as partial models. These have physical interfaces (thermal, mechanical, electrical) as well as an interface for information exchange. The individual models can be interconnected in any sequence, and executed in different levels of detail according to requirements (equation-based and/or map-based). The basis for this work is a validated component database with submodels and maps that can be varied by scaling. Using a driver who can implement both time-based and route-based driving profiles, different vehicle topologies, route profiles, and environmental conditions and their effects on driving energy demand can be evaluated in parameter studies.

Highly flexible component and system test stands

Example of a test setup: Durability test for air path components of a fuel cell system
© Fraunhofer ICT
Example of a test setup: Durability test for air path components of a fuel cell system

The test stands are designed for the experimental analysis of components or subsystems. The focus is on the reproducible and time-optimized measurement of the components and the application of specialized measurement equipment. The test stands have a (hot) air supply, and are suited, for example, to testing components of the cathode path of fuel cells (e.g. e-compressors, membrane humidifiers). In addition, the following tests are possible:

  • Durability tests for components in the cathode path of fuel cells
  • Pressure cycling test on fuel cell stacks
  • Characterization of heat pumps and adsorption chillers
  • Testing of organic Rankine cycle components and systems
  • Leak testing (with gaseous or liquid media)
  • Flow characterization (with gaseous or liquid media)

Combustion engine test stand

Engine test stand for combustion process development and functionality testing with synthetic fuels
© Fraunhofer ICT
Engine test stand for combustion process development and functionality testing with synthetic fuels

Fraunhofer ICT operates an internal combustion engine test stand for combustion process development and emission and functionality tests.

The current test stand periphery enables the use of conventional and regenerative energy sources (gaseous and liquid). Using gas mixers, fuel blends (e.g. hydrogen/methane) can be produced in any mixing ratio.

In addition to cutting-edge measurement equipment for combustion process development, innovative and specialized measurement equipment is used to solve complex challenges and validate simulation models.

A programmable prototype engine control unit enables the implementation of innovative controls with real-time capability and predictive models, in addition to classical operating strategies.

The data acquisition and data management system developed in-house includes the documentation, plausibility check and processing of the measurement data.

This enables sustainable documentation and efficient evaluation of the development scopes.

Single-cylinder engine

Flexible single-cylinder development engine for speeds up to 10,000 rpm
© Fraunhofer ICT
Flexible single-cylinder development engine for speeds up to 10,000 rpm

Several universal single-cylinder crankcases form the basis of various development engines. Specific top ends (cylinder/cylinder head) can be designed and engineered in-house to meet requirements.

Fraunhofer ICT can work with existing hardware or develop an internal combustion engine tailored to a specific research task.

Portable emission measurement system (PEMS)

Measurement with the PEMS
© Fraunhofer ICT
Measurement with the PEMS

At Fraunhofer ICT, a portable emission measurement system (PEMS) is used to determine the real emissions from combustion engines in vehicles. For this purpose, existing RDE (real driving emissions) routes can be used alongside routes tailored to the research project. The accompanying development of a digital twin at Fraunhofer ICT enables the further optimization of operating strategies, for example with regard to the thermal management system.

Warehouse, and prototype assembly

Pre-assembly of a test setup
© Fraunhofer ICT
Pre-assembly of a test setup

After receipt and quality control, project-specific components are stored in an area accessible only to specialist personnel. The retrieval process is carried out using inventory lists of components. Pre-assembly of prototypes is performed and documented by qualified personnel. A mechanical and electronics workshop is available for last-minute adjustments.

Construction of demonstrator and test vehicles including measurement and control technology

Vehicle modified at ICT-NAS
© Fraunhofer ICT
Vehicle modified at ICT-NAS

In addition to prototype assembly, Fraunhofer ICT also constructs demonstrator and test vehicles, including measurement and control technology. It is possible both to adapt existing conditioning circuits and to install new ones. The implementation of the necessary measurement and control technology, as well as the development of user interfaces (HMIs), is carried out by Fraunhofer ICT. The data measured during vehicle operation can be transferred to a protected backend via UMTS transmission in real time or with a time delay.

Mobile and flexible measurement data collection

Data logging system developed and constructed at ICT-NAS
© Fraunhofer ICT
Data logging system developed and constructed at ICT-NAS

Fraunhofer ICT has developed a versatile data logger. Its flexible configurability improves the quality of the analyzed signals. With prioritization of the recorded variables the sample rate can be increased.  In addition to parameters from internal machine and vehicle sensors, data from external sensors such as a GPS module, an accelerometer or pressure-temperature-humidity sensors can be recorded. This ensures that all measurement data required for the research task are recorded and made available in the necessary density. With its compact dimensions, the data logger can be installed in various positions.

Hot-gas test stand and high-frequency pulsator

Component test at 1,000 °C
© Fraunhofer ICT
Component test at 1,000 °C

Air and hot gas flow systems for waste heat recovery, turbochargers and exhaust gas systems are tested on the hot-gas test stand. The high reproducibility of the operating conditions forms the perfect basis for reliable measurements, and consequently enables reliable information to be obtained on the setup or system. The rapid change from hot to cold gas temperatures allows thermomechanical fatigue (TMF) tests to be performed to determine the behavior and service life of the test specimen. A special feature of the test stand is the combination of the hot-gas burner with a high frequency pulsator. This combination allows the TMF load to be superimposed with a mechanical load (high cycle fatigue) to create realistic test conditions for the components. A flexible gas pulsation device, which enables gas pulsations to be applied to the components exposed to air and hot gas, is also available on Fraunhofer ICT's hot-gas test stand.