Dynamic Testing Solutions

3. New Energy and Three-Electric (Battery, Motor, Electronics) Testing Solutions
4. Industry Background & Engineering Challenges

New energy and three-electric systems are characterized by policy drivers, rapid technological iteration, and intense market competition. For testing equipment manufacturers, this brings many challenges including high testing complexity (high power, high real-time performance), difficulty in condition simulation, stringent safety requirements, large data volumes, and the need for in-depth analysis.

Constantly changing new requirements present additional challenges during the testing and validation phase:

• Validation of charge/discharge performancebrought by rapid iteration of battery technology
• Safety and redundancy validationof battery systems under extreme conditions
• Continuously introduced new standards bring more challenges to the testing and validation phase
• Repeatable and quantifiable testingfrom component level to system level

Equipment requiring greater intelligence, smaller footprint, higher energy efficiency, lower noise, and greater safety

• For OEMs and Tier 1 suppliers, the core issue is no longer “whether testing means exist,” but rather: Can we continuously validate and improve authentically, controllably, and reproducibly in the early stages of development?

2. KTS System-Level Approach

From a “complete three-electric system testing” perspective, KTS has built a system covering:

Battery Charge/Discharge Testing → Battery Safety Testing → Drive Motor Testing → Battery Charge/Discharge HIL Testing, etc.

• This system consists of the following three layers of capability:
• High-precision actuation and high-load loading capabilities
• Multi-channel synchronous measurement and precise control capabilities
• Capability to build and integrate equipment according to standards
• These ensure that test results are not only “measurable” but also credible, benchmarkable, and usable for design decisions.

3. Core Testing Capability Modules
4. Automotive Traction Battery Crush Testing System

• Ensuring that the battery does not catch fire or explode when subjected to external pressure
• Precise control of speed, position, and load
• Test safety assurance with functions such as spraying and immersion
• Multi-variable synchronous loading and measurement including displacement, force, operating current, and operating voltage

Applicable for:

• Traction battery assemblies and components
• Crush testing of traction battery assemblies and components
• Nail penetration testing of traction battery assemblies and components

2. Automotive Traction Battery Short Circuit Testing System

• Ensuring that the battery pack or battery cell meets design requirements in the event of a short circuit
• Capable of meeting testing requirements with a maximum short-circuit current of 12,000 A
• Adjustable short-circuit resistance to meet testing needs
• High acquisition rate allowing precise capture of the short-circuit瞬间

Applicable for:

• Short-circuit testing of traction battery packs
• Short-circuit testing of traction battery cells

3. New Energy Vehicle Motor Testing

• Stall torque test
• Load test
• No-load test
• Temperature rise test
• Load characteristic test
• Efficiency characteristic test (torque-speed characteristic)
• No-load loss test of drive motor
• Overspeed test

Applicable for:

• Performance testing of new energy vehicle motors
• Reliability testing of new energy vehicle motors

4. Component-Level and System-Level HIL Joint Testing

• HIL testing of traction battery charge/discharge
• HIL simulation testing of controllers and motors
• Virtual validation of extreme and fault conditions
• By combining HIL with physical actuation systems, “road test risks” are shifted forward to be completed within the laboratory.

4. Key Technical Advantages

High-dynamic, high-precision actuation system

Servo loading system with high-bandwidth response capability

Supports force / displacement / torque multi-mode control

Meets high-frequency dynamic and impact condition testing requirements

Multi-channel synchronous control and measurement

Strict synchronization across multiple axes and channels

Supports complex coupled conditions

Ensures authenticity and consistency of system-level testing

Test conditions can be modeled and reproduced

Supports modeling of typical roads, operating conditions, and custom conditions

Test processes are repeatable, replayable, and comparable

Suitable for design validation and regression testing

Custom-oriented system integration capability

Customized according to customer chassis architecture and development stage

Supports bench testing, production line testing, and R&D testing

Can integrate with customer’s existing software and control platforms

5. Typical Application Scenarios

Testing institution R&D and validation

Including China Machinery Huanyu, etc.

Tier 1 battery system development

6. Implementation & Delivery

KTS provides complete engineering services from requirements analysis to system delivery:

• Test requirements and condition analysis
• System solution design and simulation validation
• Equipment manufacturing and system integration
• On-site installation, commissioning, and training
• Long-term technical support and system upgrades

7. Selected Case Studies
8. Automotive Traction Battery Crush Testing Solution

The mandatory national standard “Safety Requirements for Traction Batteries for Electric Vehicles” (GB38031-2025), organized for formulation by the Ministry of Industry and Information Technology, will come into effect on July 1, 2026. The latest standard requires that batteries do not catch fire or explode (alarm still required), and that smoke does not cause harm to occupants.

Crush testing of battery packs and battery cells is one of the key items for battery safety validation. The crush direction can be the X-direction or Y-direction. Crush speed: not greater than 2 mm/s. Crush extent: Stop crushing when the crush force reaches 100 kN or the crush deformation reaches 30% of the overall dimension in the crush direction. Holding time: 10 minutes (configurable).

The system can perform real-time acquisition and storage of crush force, displacement, voltage, and other parameters during the test.

2. Automotive Traction Battery Short Circuit Testing Solution

To ensure consumer life and property safety and support high-quality, healthy industrial development, the battery should not catch fire or explode in the event of a short circuit in an automotive traction battery. The equipment enables short-circuit testing of battery packs or cells, with a short-circuit voltage of up to 1000 V and a maximum short-circuit current of 12,000 amperes.

At the start of the test, all protection devices that affect the function of the test object and are related to the test results should be in normal operating condition. The equipment’s short-circuit resistance should not exceed 5 mΩ. Maintain the short-circuit condition until any of the following conditions are met, at which point the test ends: the protection function of the test object activates and terminates the short-circuit current; after the外壳 temperature of the test object stabilizes (temperature change less than 4°C within 2 hours), continue short-circuiting for at least 1 hour.

The equipment’s acquisition rate can reach over 10 kHz, enabling capture and acquisition of current changes at the moment of short circuit.

3. Automotive Traction Battery Fire Testing Solution

The equipment enables fire testing of battery packs, requiring that the test specimen does not explode under actual fire conditions. The test method follows the national standard GB38031-2025 “Safety Requirements for Traction Batteries for Electric Vehicles.”

During the test, the flat plate containing gasoline exceeds the horizontal projection dimensions of the test object by 20 cm to 50 cm. The height of the flat plate is not more than 8 cm above the gasoline surface. The test object should be placed centrally. The distance from the gasoline liquid level to the bottom of the test object is set to 50 cm, or to the ride height of the bottom surface of the test object under vehicle no-load conditions. Water is injected into the bottom layer of the flat plate.

External fire testing can be divided into four stages: preheating, direct burning, indirect burning. The process is fully automatic to ensure personnel safety, and the process time and parameters are configurable.

4. Automotive Traction Battery Bottom Ball Impact Testing Solution

The equipment enables bottom ball impact testing, requiring that the test specimen does not explode under bottom impact conditions. The test method follows the national standard GB38031-2025 “Safety Requirements for Traction Batteries for Electric Vehicles.”

The test requires a ball impact speed of 1 mm/s (configurable from 1 to 10 mm/s), impacting the bottom position of the traction battery pack with a metal ball head of 150 mm diameter (as specified in the enterprise standards of various OEMs and component manufacturers). Impact is applied until reaching 110% of the fully loaded vehicle weight corresponding to the traction battery or 20 kN (whichever is lower), followed by a hold of 10 minutes (configurable).

The equipment’s maximum crush force can reach 45 kN, accommodating battery dimensions of 2500 mm × 2300 mm × 300 mm (length × width × height).

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5. New Energy Vehicle Motor Testing Solution

This solution is primarily used for performance and reliability testing of drive motor systems. The equipment adopts advanced technology and processes, offering superior performance including high accuracy, high reliability, easy maintenance, and high safety. The配套 measurement and control software enables automatic (or manual) execution of various test items, and can process and analyze the collected data, outputting relevant charts and curves. It is widely used in the field of drive motor testing.

The chassis dynamometer enables the following test items:

• Stall torque test
• Load test
• No-load test
• Temperature rise test
• Load characteristic test
• Efficiency characteristic test (torque-speed characteristic)
• No-load loss test of drive motor
• Overspeed test
• Reliability test
• Short-term overvoltage test
• Electric drive condition test (automatically generates curve graphs)
• Power generation condition test (automatically generates curve graphs)
• Efficiency MAP diagram
• Road simulation test

8. Contact & Customized Solution

If you are currently developing chassis systems or steer-by-wire chassis-related products, please contact the KTS engineering team. We will provide you with:

• Testing solution recommendations tailored to your specific system architecture
• Customized test system design
• Engineering-level technical communication and support