The key to this innovation lies in spatial separation: while the complete vehicle operates outside the test cell, the E-axle is measured within a Class 1 acoustic chamber. This method combines realistic test conditions with precise acoustic measurements – all without the need for complex residual bus simulation.

By eliminating the simulation of vehicle communication, this approach not only saves time but also significantly reduces the complexity of the tests. The result: efficient benchmark investigations with maximum reliability.

Working with high-voltage batteries demands the highest safety standards. To mitigate even minimal residual risks under demanding conditions, an AVL battery fire extinguishing system is implemented. This system provides a dependable safety mechanism, enabling worry-free test operations.

Another technical highlight is the connection between the vehicle and the acoustic chamber. This is achieved through cable extensions spanning over 25 meters. The distance allows for flexible arrangement of test components and avoids spatial constraints caused by physical separation.

Benefits

• Realistic Test Conditions: The E-axle is tested in the acoustic chamber while the benchmark vehicle operates under normal conditions.
• No Residual Bus Simulation: Direct connection to the vehicle eliminates the effort needed for system communication simulation.
• Enhanced Safety: The AVL battery fire extinguishing system ensures secure handling of high-voltage components.
• Maximum Flexibility: Cable extensions enable optimal utilization of test benches and acoustic chambers.

With this innovative testing methodology, VIRTUAL VEHICLE, in cooperation with AVL, sets new benchmarks in the development of electric drivetrain components. The combination of efficiency, safety, and precision enables E-axles to be tested under realistic conditions – without compromises in time or resources.

This approach marks a significant step toward optimized, future-oriented vehicle development. A breakthrough that not only enhances the quality of test results but also strengthens the industry’s capacity for innovation.