Chroma introduces the Chroma 1210 E-Propulsion Test System, designed for both passenger and commercial electric vehicle (EV) applications. This system provides comprehensive simulation and testing for EV powertrains, including e-motors, motor drivers, transmissions, and e-drive systems.

The Chroma 1210 is primarily used for performance calibration and verification of automotive powertrains. It offers the capability to integrate whole-vehicle dynamic models for simulating and validating mechanical components. The system supports both manual and programmed operation, with synchronized recording of critical physical parameters such as voltage, current, power, speed, torque, and temperature. During testing, generated power is fed back to the grid via Chroma's regenerative bidirectional DC power supplies (17040 and 62000D series). The 1210 also features battery simulation, allowing real-time emulation of battery response characteristics during vehicle operation for highly reliable verification.

The E-Propulsion Test System has 4-quadrant operation capability, maintaining constant torque loading below rated speed (including zero speed and reverse), and constant power loading above rated speed. The test bench employs an integrated mechanical design, using modal analysis to simulate stress and resonance. It supports full-speed range testing and features a modular clamping system that accommodates a variety of motors under test. Comprehensive safety mechanisms include overcurrent, overvoltage, undervoltage, and short-circuit protections, as well as power phase-loss detection, temperature monitoring, and overload response warnings. The complementary E-Propulsion Test software features DBC file loading, manual control, and data monitoring. The testing interface supports real-time waveform display, showing 2D graphs of speed, voltage, current, and other values against time, with configurable data sampling rates.

The 1210 system can run preset operating conditions. By importing CSV files, users can define test voltage values, current protection values, motor (load side) speed commands, motor (DUT) torque commands, and other control parameters corresponding to time conditions. Test reports include customizable charts, generating information such as product name, test date, and test parameters. For user-selected test data, the system can produce time-based parameter curves and efficiency maps for motors and motor drivers.

Built on an open software architecture, the Chroma 1210 seamlessly integrates with existing lab equipment and safety monitoring systems. Its built-in vibration monitoring ensures comprehensive oversight of both the test bench and device under test, making it an ideal solution for modern testing facilities seeking to streamline their operations through unified laboratory integration and management.

The vibration monitor unit measures vibrations from the dynamometer's motor, bearing housing, and the device under test (DUT). It monitors and records vibrations during testing, issuing alarms or halting the test if vibrations exceed safe limits. This ensures the safety and stability of the testing process while verifying compliance with specific vibration standards and regulations.

Chroma's E-Propulsion Test software features a real-time control system that can manage DUT motor drivers and supports various communication protocols including CAN, CAN FD, and EtherCAT. The software accommodates a wide range of testing applications from powertrain performance testing to durability trials. Users can create automated tests through scripting and set up customized test scenarios to meet diverse validation requirements. The software comes equipped with comprehensive tools for system warnings, protection mechanisms, data processing and storage, waveform display, and report generation. Its graphical interface for data monitoring can be customized to cater to specific needs. For simulation of dynamic, real-world driving conditions, the software supports integration of Simulink-based real-time vehicle models. This allows for validation using international testing standards such as NEDC and WLTP for automotive power systems. Additionally, the software can simulate EV batteries, using actual mechanical energy consumption and recovery to validate battery management systems and calculate overall vehicle range.

▲ System Control Interface

▲ Data Monitor Interface

The E-Propulsion Test software can measure various motors and motor drivers with fully synchronized data acquisition. This comprehensive approach enables detailed analysis of different electric drive systems (single motor, motor-generator combinations, etc.) while accounting for additional loads (heating, air conditioning, 24V and 12V systems). In typical EV testing, motor drivers operate at different switching frequencies depending on driving conditions (urban traffic vs. long-distance mountain roads) to optimize efficiency. In real-world conditions, numerous factors determine energy consumption, including environmental conditions (temperature, weather), road conditions (uphill, downhill, urban streets, mountain roads, mixed terrain), road quality, and different driving habits. Chroma's E-Propulsion Test software can measure and analyze the impact of all these parameters simultaneously during testing, providing a comprehensive understanding of vehicle performance under various real-world conditions.

▲ System Efficiency Graph

▲ FTP-75 Test Result

▲ 3D Report Output

System security protection - extending equipment life

• Comprehensive protection mechanisms including overcurrent, overvoltage, undervoltage, short circuit, power phase loss detection, and system temperature monitoring, with overload warning responses.
• Dual loop mode protection system for enhanced operating safety.
• Voltage and current measurement for DUT motors and motor drivers, with configurable safety threshold values. Equipped with a Vibration Monitor Unit for real-time monitoring of both the test system and DUT. In case of system abnormalities, immediate feedback is sent to the control terminal, triggering alarms or system shutdown to protect the DUT and testing equipment.

 Simultaneous data measurement - improving experiment reliability

• Real-time monitoring interface displays instantaneous values including voltage, current, rotation speed, torque, input power, output power, efficiency, and temperature.
• Synchronized data collection with adjustable sampling rates to meet different testing requirements.
• Optional synchronized collection of CAN/CAN FD data and other physical measurements.

 Test part vibration analysis - reducing motor abnormalities

• Real-Time Detection: Reliable automated fault diagnostics.
• Quality Assurance Testing: Continuous monitoring of DUTs, reducing testing time for defective products.