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LINK Introduces First-of-its-Kind Hub Motor Test System for the EV/PHEV Industry

Apr 16, 2021

The Model 6642 hub motor is shown here.

Link Engineering Company is the leader in customized solutions, setting the standard for testing equipment and testing services, including the testing of emerging transportation technologies like Electric Vehicles and ADAS Systems. With involvement in e-mobility testing ranging from the powertrain, battery systems, NVH, and braking, LINK has added a new, state-of-the-art hub motor test system to its portfolio.

Introducing LINK’s new Hub Motor and NVH Test System, the Model 6642, a complete motor test solution for the Electric Vehicle and Plug-in Hybrid Electric Vehicle (EV/PHEV) industry.

Recent developments with In-Wheel Motor (IWM) propulsion systems now being used on certain production EV’s have driven a greater demand for advanced testing solutions within the laboratory. LINK’s experience and developed control technologies for testing electric motors, brake systems, and regenerative braking have led to the natural integration of all these capabilities into one. This allows testing of the complete IWM system on a single dynamometer, controlling a total driving cycle, including acceleration and braking maneuvers.

LINK’s Hub Motor and NVH Test System is a dual function or combined torque and speed test system specifically designed for EV/PHEV vehicle technology. The Model 6642 integrates both hydraulic braking and motor drive testing into a combined operation. The system can perform extensive motor characterization, run full hydraulic friction brake tests, and operate in combined or blended modes between the two subsystems. This new ability to operate both hydraulic braking and motor drive capabilities opens up countless opportunities for EV manufacturers to optimize or fully develop both systems simultaneously. For accurate NVH characterization, the Model 6642 includes an environmental sound chamber that precisely measures noises from the motor or hydraulic brake systems, allowing for testing at extreme temperature and humidity settings.

Being a comprehensive In-Wheel Motor (IWM) solution, the Model 6642 also simulates actual vehicle conditions. IWM’s operate within the wheel of the electric vehicle, unlike standard motor applications that are not subjected to this environment of extreme temperature, vibration, loading, and contamination. This means the IWM has to pass not only the motor performance requirements for the vehicle, but do so under typical chassis systems requirements as well. The Model 6642 can replicate the environmental conditions of temperature and humidity, plus a wide range of motor fluid cooling and heating. To assist with this testing, available upgrades include adding water spray, contaminants such as salt slurry, and Road Load Simulation (RLS), which provides additional capabilities to represent actual vehicle maneuvers like cornering.

Possessing years of testing experience across a wide range of industries and applications, LINK has a deep understanding of vehicle test equipment and software development. This diverse expertise has naturally progressed into the EV/PHEV industry. LINK’s global footprint accommodates regional and international electric vehicle testing standards and allows for the quick integration of advanced solutions. LINK delivers extensive EV equipment and laboratory testing services ranging from performance dynamometers, high RPM gearbox and motor testing, power electronics testing, NVH testing of e-machines, and more. From component level to full vehicle testing, LINK is the premier resource for electric vehicle testing needs. Read about LINK’s e-mobility testing efforts and find out more about the Model 6642 on our website.

Link Engineering Company is a global organization dedicated to the design and manufacturing of precision test systems. LINK’s in-house design and manufacturing capabilities range from full mechanical, electrical, and software design to fabrication, assembly, and acceptance. Headquartered in Plymouth, Michigan, near Detroit, LINK has capitalized on that strong foundation of craftsmanship for 85 years, and now operates 22 facilities in 7 countries across the globe.

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Brakes

Type of TestTest HighlightsEquipment UsedExample Procedures
Chemical TestingMeasurement of copper, asbestos and other elements in brake friction materialsICP-OES / PLMJ2975
Materials TestingPhysical properties including quality control for friction, wear, compressive strain, shear strength, corrosion resistance, swell and growthChase Machine / Compressibility Machine/ Shear Machine / Corrosion Chamber / Environmental Chamber / OvenJ661, ISO 6310, ISO 6311, ISO 6312, ABNT NBR 9301, ABNT NBR 5505, ABNT NBR 5537, ASTM B117
Frequency ResponseComponent Frequency ResponseLaser Vibrometer Test StandSAE J2933, J3001, J2598, L-4375
Structural Fatigue and
Durability
Breaking strength, cyclic fatigueServo Hydraulics, Torque FlexJ2995, C419, C441, GMW18022
Caliper FingerprintingCaliper characteristics such as knockback, rollback, fluid displacement, deflection...Caliper Test Bench / Brake DynamometerL-4177, PF.90257
Brake Drag and DTVResidual drag, disc thickness variation, brake feel and vehicle fuel mileageOff Brake Drag Stand / Brake DynamometerJ2923, GMW14926, GMW14351, PF.90257, L-13080
PerformanceHydraulic, air and electric brakes, friction levels, stopping distance, corrosion, cleanability, brake torque variation, rotor cracking, regulation, stability control, coastdownBrake Dynamometer, Model 4000 DASJ2784, J2928 IS026867, GMW14985, PF.90210, PF.90244, L-405, FMVSS 121, FMVSS 122, FMVSS 105, FMVSS 135, FMVSS 126, FMVSS 136, ECE R13H, AMS
WearRotor wear, drum wear, lining wear, DTV, durability, city traffic, suburban trafficBrake Dynamometer, Model 4000 DASJ2707, USCT, L-423, PF.90244, Los Angeles, Detroit, Phoenix, Birmingham, Marquette
NVHBrake squeal during drag and decel events at different temperatures, pressure and torque levelsNVH Brake DynamometerJ2521, L420, 1430, GMW17427, PF. 90244
Brake EmissionsBrake dust particle size, count, concentration and massBrake DynamometerWLTP, CARB, Duty cycle

Hubs/Bearings

Type of TestTest HighlightsEquipment UsedExample Procedures
Wheel BearingWater intrusion and durability when exposed to mud and saltBearing Test StandLINK Hub and Bearing, GMW16306, GMW16310
Passenger car, sport/performance and open bed vehicle wheel bearing spallingBearing Test StandGMW16311, GMW16308, GMW16309
Brinelling resistance validates long-term reliability/durabilityBearing Test StandGMW16305
Rotary fatigue lifeRotary Fatigue MachineGMW16325
Wheel HubRotary bending fatigue life characteristicsRotary Fatigue MachineGMW14249
Hub/BearingEvaluate hub and bearing performance, durability, seals and NVH when exposed to extreme environmental effects such as temperature and mud/salt solutionBearing Test Stand/Rotary FatigueTIP-000037A, LINK Hub and Bearing, SAE J1095, LINK Impact
Hub FatigueHub fatigue using biaxial loadingBiaxial Test StandSAE J2562

Wheels

Type of TestTest HighlightsEquipment UsedExample Procedures
ChemicalEvaluates filiform corrosion on painted aluminum wheels and painted aluminum trimICP-OESASTM E3061
Wheel Corrosion and CoatingsEvaluates filiform corrosion, tape adhesion, degree of rusting on painted aluminum wheels and painted aluminum trimCorrosion ChamberSAE J2635, ASTM B368, ISO 9227,
ISO 2409, ASTM D3599,
ABNT NBR 11003, ASTM D610,
ASTM D1654
Wheel FatigueLoad simulation test of aluminum alloy wheelsBiaxialBMW QV36026, SAE J2562, FORD
L-307, GMW14340
Dynamic Cornering Fatigue and Dynamic Radial Fatigue - Steel wheelsEccentric Mass and RadialABNT NBR 6750
Rotational fatigue, Radial load fatigue and biaxial load fatigue of steel and aluminum wheelsEccentric Mass, Radial and BiaxialABNT NBR 6751
Dynamic Cornering Fatigue and Dynamic Radial Fatigue and Impact resistance of temporary use and normal highway use aluminum wheelsEccentric Mass, Radial and Drop TestABNT NBR 6752
Wheel Radial FatigueRadialGMW14909
Wheel ImpactWheel Inboard Rim Flange Vertical ImpactDrop TestGMW15321
Wheel radial impactDrop TestCETP 04.04-L300
Wheel Lateral ImpactDrop TestGMW14910, SAE J175
Wheel StiffnessFrequency Response Function (FRF)Frequency ResponseGMW14876
Deformation of the wheelServo HydraulicsJ2315
Center cap heat
resistance
Center Cap deformation under elevated temperature conditionsBench TestBrake Heat Center Cap

Tires

Type of TestTest HighlightsEquipment UsedExample Procedures
Parking ForcesAllows proper sizing of power steering componentsForce and MotionLINK Parking Forces
Tire FootprintDetermines the contact patch geometryForce and MotionTire Footprint
Tire Modeling
Determine tire inertia which is then used Ftire and other models and simulationsInertia MachineLINK Tire Inertial Properties
On-center parking effort test for Ftire inputForce and MotionSWP
Determine static stiffness (X, Y, Z, Alpha) for Ftire inputStatic Stiffness MachineSAE Static Stiffness
Determine how the tire envelopes an obstacleCleat MachineJ2731
Measure the forces and moments generated at a high frequency response spindle when the tire impacts a cleatCleat MachineJ2730
Braking and Cornering PerformanceDetermine the straight line braking performance of a tireForce and MotionJ2673
Determine the free rolling cornering properties of a tireForce and MotionSAE TIME, J1987, SWP
Measure the combined cornering and braking performance of a tireForce and MotionJ2675
Tire StiffnessMeasure rolling vertical stiffness of a tire at speedRolling Vertical Stiffness
Rolling ResistanceMeasure tire rolling resistance using a drumForce and Motion, Rolling ResistanceJ1269, J2452
Tire WearAssess tire wear in the labForce and MotionLINK Wear Test
Tire NVHTest tire sizzle, cornering noise, pass-by noise, steering wheel dither, freeze crack impacts, high speed uniformity and imbalance sensitivityForce and Motion, Dynamometer, Model 4000 DASNoise, Vibration, Harshness