The engineers at MAE developed the MAE-AC-4000 Series Test Stand for R&D, Calibration, Certification, End-Of-Line, and Repair/Maintenance testing applications. This new universal automotive test stand was designed to rigorously and efficiently test the next generation of electric and hybrid vehicles as they are developed, calibrated, certified and then roll off your production lines.
Download our latest brochure about the MAE-AWD-400-AC-EC Series (PDF)
Standard Features
- Universal Automotive Test Stand
- 2WD & AWD Vehicles
- Adjustable Wheelbase (90-140”)
- Independent AC Motor per Roll Set
- Electric Hybrid Systems Development
- Calibration & Certification
- EOL Production Testing
- Regeneration Testing
- Inertia Simulation
- ABS Braking/ESC Skid Simulation
- Thermal Imaging & Vibration Analysis
- Designed for all EV, BEV, HEV, PHEV, FCEV
One Universal Test Stand designed to do it all – Smarter by Design.
MAE’s latest product for the development, calibration, certification, End-of-line and repair & maintenance testing of electric and hybrid vehicles is the MAE-AC-4000 Series Universal Automotive Test Stand. This new universal tester is an advanced independent-wheel-control AC motor dynamometer and ABS/ESC tester that is capable of reproducing an unlimited array of testing and simulation conditions for full product life cycle testing of electric and hybrid vehicles and vehicle sub-systems.
The AC-4000 utilizes four independent AC motors, one coupled to each set of rollers, to control the load to each wheel independently. A moveable wheelbase system allows the AC-4000 to accommodate both 2WD and AWD vehicles with wheelbases ranging from 90-140”. An automatic vehicle restraint and safety system greatly reduces the test cycle time and ensures that vehicles remain safely in position on the tester.
HEV R&D, Calibration, Certification
For vehicle development, calibration and certification applications, the AC-4000 Series provides a cost-effective design and enables quick development cycles for performing initial hybrid and electric vehicle calibrations, traction system motoring and ABS/ESC testing with skid simulation, regenerative braking and limited traction condition simulations using road load and federal drive cycles, electrical power systems analysis, HEV/PHEV/EV controller development, efficiency testing, fuel consumption testing, repair & maintenance and other complete vehicle or sub systems evaluations. MAE offers a number of lab-grade software and data acquisition packages for Hardware-in-the-loop and R&D environments.
End-Of-Line Production Testing
As a EOL test stand, the MAE-AC-4000 Series offers a flexible solution for test control, data acquisition and operator interface, stepping test operators through each step of an automated EOL test sequence in a simple and user-friendly format, while collecting, analyzing and reporting on vehicle systems status and performance data. MAE’s AC-4000 test stand communicates with each vehicle via CAN communication to determine pass/fail results and to establish certain vehicle systems statuses as required during the test procedure. The flexibility of MAE’s systems allows us to easily adapt to meet unlimited test procedures and simulation requirements.
MAE’s experience and expertise with sophisticated End-of-Line systems stems from having supplied a host of fully-integrated, automated testing solutions for a wide range of EOL testing applications. MAE offers completely customized end of line testing solutions for your specific end of line testing applications.
MAE can easily customize an automated EOL test sequence to meet your EOL testing requirements.
Specifications
| Roll Diameter: | 8.575” (217.805 mm) |
| Roller Surface: | Knurled (STANDARD), Chrome (OPTIONAL) |
| Rolls and Inertia Weight Balance Specification: | ISO DR1940 G3.0 |
| Rotation: | Bi-Directional |
| Operating Speed Range: | 0-80 mph |
| Roll Speed Accuracy: | > 0.1 mph |
| Power Conversion Unit (PCU) Type: | AC Inverter Duty Motor/Generator |
| PCU Size: | Continous Duty: 75-hp @1150 – 3200 rpm (x4)Intermittent Duty: 150% of continuous duty for 1 out of 5 minutes |
| PCU Cooling: | Forced air fan cooled |
| PCU Speed Sensor: | The PCU shall have an independent speed sensor dedicated for the control of the PCU. This speed sensor shall have at a minimum 1,024 pulses/rev. |
| PCU Thermal Overload: | Thermal switch wired normally closed |
| Inverter Online Power Regeneration (standard): | Power Module to regenerate power back onto supply power lines instead of into the Power Dissipation Coil. |
| Line Reactance: | The Inverter/Controller has a small amount of line reactance built in. This reactance helps balance and reduces noise injected back into the supply circuits. Additional external line reactance can be installed as an option. |
| Inertia Selection Increment: | 1 lb. for simulation |
| PCU Force Measuring Accuracy: | In-line Torque Meter ± 833 lb.ftAccuracy Class: ±0.1% of rated output at all values ± 10-100% of rated output. |
| Inverter/Controller: | Self contained controller specifically designed to operate the PCU and the Power Regeneration System (Inverter Power Dissipation Coils). This is the heart of the power control section of the system. The controller has many built in features to observe the environment around it, such as: PCU Over Current, PCU Over Temperature, PCU Power Dissipation Coils over Temperature (if Used), Supply Power Phase Loss, PCU Short Circuit Protection, PCU Supply Voltage, PCU Over Speed, PCU Supply Current. |
| Road Load Increments: | 0.1 hp @ 50 mph or to the precision of the vehicle loading coefficients. |
| Vehicle Loading (Trans): | TRLHP@Obmph = {Av * Obmph} + {Bv * Obmph2} + {Cv * Obmph3}Where: TRLHP = Track Road Load Horse PowerObmph = Observed mphAv , Bv , Cv = Road Load Coefficients |
| Wheelbase Movement: | Gearmotor |
| Wheelbase Range: | 90 – 140 Inches (2286 – 3556 mm) |
| Vehicle Restraint System: | Automatic pop-up roller restraints |
| Ambient Temperature Range: | 68 to 86° F, 10-95% relative humidity (non-condensing). The system is intended for use in a climate controlled laboratory environment with adequate air ventilation and exhaust removal systems (optional by MAE). |
| Machine Shipping Weight: | 16,000 lbs. (7257 kg) |
Options and Accessories
- Exhaust removal systems
- Vehicle cooling systems & Fuel control systems
- ECM read/write control interfaces
- Charging and starting systems
- Boom arm closed interconnect and operator interface panels
- Conveyor system interface
- Factory automation system interfaces
- Fire and sound suppression systems
- Thermal Imaging Integration
- Vibration Analysis