Truck & Off-Highway Engineering - August 2021 - 19

TESTING FEATURE
Light-duty axle testing
using the 3E Rig.
for electric and hybrid vehicle development and hardware
in the loop (HIL) testing. It also houses a hydraulic
test stand for hydraulic valve body development, a 2/1E
transmission efficiency rig, and a 1E spin/tilt rig providing
enhanced lubrication flow analysis capability.
Hole said the company's U.S. facility is booked about
four to five months out for its larger loaded dynos. For
some of the smaller dynos used for lubrication development
and efficiency characterization, the company has
limited availability over the coming months. " This is a
time where these types of non-commodity, development
partner facilities are under great demand in Metro
Detroit and across the whole U.S., " Hole said.
So, is this testing surge the new normal? " We definitely
see a continuation of the demand for the foreseeable
future and are planning further significant investments
throughout the next year or so to accommodate
this demand, " Hole shared. " We also see a
strong drive towards higher voltages and also additional
power sources like hydrogen. "
DSD currently does not have its own testing equipment
for fuel cells but has partners it can leverage for
this type of product today. " We think that hydrogen
fuel cells will be significant in the heavy truck market,
and the need to have the facilities to be able to test
the complete system is something we are watching
carefully as we look toward the future, " he said.
Lessons learned
The engineering team at DSD has learned many lessons
through the course of testing and development
for electric propulsion. One notable insight is not to
TRUCK & OFF-HIGHWAY ENGINEERING
Commercial-vehicle motor testing conducted on a dedicated motor development rig.
underestimate the challenge of testing motors at high speed. " It's a
significant mechanical challenge with several modes of vibration that
you need to avoid in order to achieve successful data, " Hole said.
Being mindful of the system limits when planning the testing also
is key. " Our customers regularly ask us to run the types of accelerated
testing that have become common practice in engine and transmission
development, " Hole explained. " This can mean the motors
within the electric drive unit are operating outside of a comfortable
window and failures are therefore common. "
Since DSD specializes in the rapid engineering and development of
complete electrified propulsion systems, its facilities allow a customer
August 2021 19
Truck & Off-Highway Engineering - August 2021

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