Chroma introduces the 1220 E-Axle Test System, specifically designed for performance and durability verification of three-in-one systems comprising motors, motor drivers, and transmissions in both passenger and commercial electric vehicles. It accommodates dual-axle low-speed, high-torque applications, running various dynamic and static functions while simultaneously saving load test results and measuring data including voltage, current, power, torque, and speed.

The Chroma 1220 integrates a dynamometer test platform, variable frequency drive cabinet, measurement instrument cabinet, main control computer cabinet, bidirectional power supply, and other peripheral equipment. Power generated during testing is fed back to the grid via Chroma's regenerative bidirectional DC power supplies (17040 and 62000D series). The included battery simulator allows real-time emulation of battery response characteristics during vehicle operation for highly reliable verification.

The system has 4-quadrant operation capability, allowing torque and rotational speed control modes to be switched as needed. It supports independent control of a single dynamometer or synchronized control of two units for full-speed range testing. The test bench employs an integrated mechanical design that uses modal analysis to simulate stress and resonance. For mobility, a handheld controller enables adjusting the horizontal positions of the two dynamometers independently. The mounting bracket has adjustable height supports and adapters that ensure stability, with appropriate couplings designed for test component installation.

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 1220 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 1220 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 test platform features X-axis movement capability, supporting a maximum single-axis travel of 600mm. It is equipped with four independently adjustable support feet for securing the DUT. These feet are aligned with the cast iron base as the reference point, offering a maximum Y-axis travel of 900mm. The system also allows for Z-axis adjustments through height regulators, with a maximum travel of 150mm. Combined with appropriate adapter brackets, the powertrain assembly under test can be securely mounted on the platform, ensuring installation consistent with real vehicle configurations. The included handheld controller enables independent adjustments to the horizontal movement distances of the two dynamometers.

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 (E-Axle) 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

▲ Test Result

▲ 3D Report Output

Safety Protection - Extending Equipment Lifespan

• 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.

 Synchronized Data Acquisition- Enhancing Test 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.

 DUT Vibration Analysis - Reducing Motor Quality Issues

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