Drive System Design (DSD), is to expand its evaluation facilities, adding two further test cells for high-performance hybrid axles and e-machines.

The move reflects a growing demand for outsourced test capacity suitable for electrified powertrains.

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The first of the new facilities can deliver input torque up to 2,500Nm at 2,100rpm, 525kW at 7,000rpm and 350kW 1,100V of battery emulation, with the second for e-machines up to 350kW and 25,000rpm. The new cells complement existing DSD facilities, which include a 450kW highly transient ETPS (Engine Torque Pulse Simulator) machine and three battery emulators.

“The recent Covid-19 pandemic has put an ever-bigger spotlight on our environment and recent government announcements on ICE restrictions is resulting in a faster shift to electrified vehicles than first anticipated,” said DSD director, David Kelly.

“There is a significant increase in demand globally, not only for design and development work but also for outsourced testing. The additional facilities will extend our ability to provide this for a wide range of hybrid and electric powertrains.

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“We are in the middle of a sea change in the industry, as the major players allocate more of their manufacturing to electrified vehicles. Companies like DSD can provide vital additional resource to help satisfy short-term peaks in testing demand as this change in policy takes effect.”

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DSD is developing its automation capabilities within the facility to help speed up testing. This has proven effective in the case of hot and cold environment testing, notes the company.

According to Kelly, tests which previously took six weeks to complete can be finished in half the time with suitably configured automatic control.