Test Systems and Sensor Technology

Testing until you get a winning race car

Is the car ready for the racetrack, or not? This question is answered in the test phase, making highly representative and reliable test systems all the more important. AVL RACETECH supplies extensive test solutions, instruments and systems, including services and support.

The full AVL portfolio for the motorsport industry includes solutions for:

  • Engine and propulsion unit
    Testbeds, from single-cylinder engines to highly-dynamic racing engines and power units
  • Transmission
    Tools for improving efficiency and optimizing shift times
  • Propulsion system
    Testbeds for single-axle and four-wheel drive vehicles
  • Whole vehicle
    Realistic test environment away from the racetrack
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Testing individual components

With all motorsport applications, our customers must be able to rely on every individual component. In order to achieve the best possible results on race day, performance-related components must be examined thoroughly. AVL RACETECH has the tools required for analysis and optimization.

We test all the elements of the propulsion system:

  • Brakes
  • Wheel and e-motor bearings
  • Lubricants
  • Fuel systems
  • Radiator

Testing the whole racecar

Our multifunctional testbed 503 allows the entire racecar to be run – no matter whether it has an internal combustion engine, hybrid drive, or electric drive. The high-tech facility is designed for extreme acceleration and deceleration values, meaning it covers all current and future motorsport requirements. On the 503, the interactions of the individual vehicle components are absolutely identical to use on the racetrack. The option to directly connect the testbed to the AVL driving simulator makes the testbed even more realistic.

Highlights of AVL RACETECH testbed 503:

  • Complete vehicle tests with Driver-in-the-Loop
  • Wheel dynos with maximum outputs of up to 1200 kW per wheel
  • Highly realistic tests for racetrack-specific setups and optimizations
  • Optional connection to AVL driving simulator with AVL VSMTM RACE software

Electrification and hybrid

E-motors are used in an ever-increasing number of motor racing categories – not just Formula E. For this reason, AVL provides test systems for developing high-performance, electrified propulsion systems, as required for the extreme demands of motorsport.

Our portfolio for testing e-motors comprises:

  • DC-supplies/battery emulators
  • E-motor testbeds for up to 125,000 rpms
  • E-motor emulators
  • Battery testbeds
  • Conditioning systems
  • Instruments
  • Safety equipment

Fuel cells and combustion engine

As well as conventional combustion engines, hydrogen offers a sustainable zero-emission option, which can also be used safely and competitively in motorsport. AVL has a wealth of expertise in both fields, which we use to support our customers in developing new systems and modifying existing ones. The test systems required to achieve this meet the highest safety standards – for example, AVL HyTron™ for testing and developing fuel cell systems.

The equipment for our test cells is ideally prepared for hydrogen applications:

  • H2 sensors
  • Dedicated ventilation systems
  • Fire extinguisher systems
  • Tried-and-tested safety routines

Sensor systems to meet the highest demands

Sensors are among the most important components in the measurement chain. For developing high-performance race cars and motorsport components, we use the full range of modern sensor technology in our tests. In doing so, we take extremely precise measurements and make the complex thermodynamic processes in the engine visible and comprehensible. In this area, we work closely with Piezocryst, a company that specializes in high-performance sensors and belongs to the AVL Group.

The following are used:

  • High-precision sensors for combustion development
  • Onboard sensors for combustion control
  • Highly dynamic and accurate GaPO4 pressure sensors for temperatures up to 700 degrees Celsius
  • Customized brake torque sensors, which can be adapted to any brake geometry
  • Dynamic torque transducer as a mechanical counterpart to e-power analysis – the fastest in the world
  • Other piezoelectric sensors for specific applications