Our Facilities
We collaborate with clients to fast-track the development process throughout the project lifecycle.
Our in-house testing and development facilities are located within our tech centres in the UK, US, and India.
We verify turnkey design projects and provide independent testing for powertrain systems. Our flexible, creative approach to development and test engineering allows us to deliver innovative solutions and accommodate bespoke test requirements.
Our skilled engineers specialise in the test and development of full-system EV propulsion and transmissions, electric motors, power electronics, subsystems, components, and prototypes. We offer virtual analysis, test rig set-up, comprehensive testing, optimisation, and result correlation tailored to your needs.
We do far more than just test at DSD. Our team of experts conduct root-cause analysis to identify issues, and collaborate with internal and external project stakeholders to solve product challenges and enhance performance. This accelerates development, saving you time and money.
Our Facilities
DSD offers EDU and transmission dyno testing, power electronics development with EMC and Hardware-in-the-Loop systems, thermal, lubrication, efficiency, subsystem testing and much more at our Michigan, US centre (22,000sq ft) and our Warwickshire, UK centre (20,000sq ft).
Full System – EV Propulsion & Transmissions
We provide controlled test environments that accurately replicate vehicle operating conditions and duty cycles. Our flexible rig layouts are designed to accommodate various driveline and propulsion system architectures. The integration of wider powertrain and vehicle systems optimises performance.
Test Rigs
UK:
- 1 x 2E – 200kW, 2000 Nm/wheel
- 1 x 3E – 1100V, 400kW, 4000 Nm/wheel
- 1 x 3E – 1100V, 260kW, 3300 Nm/wheel
- 1 x 2E – 1100V, 260kW, 3300 Nm/wheel
US:
- 1 x Electrified 3E – 400 kW, 4000 Nm/wheel
- 1 x Electrified 2E/3E – 2.1 MW, 13,000 Nm/wheel
Equipment
- Battery emulators (sync / source)
- Industry leading power analysers and current transducers
- High accuracy torque transducers
- HV instrumentation
- Vibration monitoring
Services
- Performance characterisation
- Efficiency mapping
- Dynamic drive cycles
- NVH assessment and optimisation
- Development durability
- Thermal performance
Electric Motor Development and Test
DSD’s controlled test environments permit four-quadrant testing. Our low-inertia, highly dynamic dynamometers are directly coupled to the test article. The integration of control systems and inverters with rig control enables highly automated, unmanned testing.
Test Rigs
UK:
- 1 x 377 kW – 20,000 RPM, 460 Nm
- 1 x 314 kW – 10,000 RPM, 700 Nm
- 1 x 600 kW – 24,000 RPM, 1000 Nm
US:
- 1 x 600 kW – 24,000 RPM, 1000 Nm
- 1 x 300 kW – 10,000 RPM, 500 Nm
Equipment
- DSD Open Platform Inverter
- Battery emulators (sink/source)
- Industry leading power analysers and current transducers
- High accuracy torque transducers
- HV instrumentation
- Vibration monitoring
Services
- MTPA mapping
- Dynamic drive cycles
- Peak power / torque
- Calibration development
- Electrical function
- Thermal performance
- Efficiency calculations
- Performance simulations
- Id/Iq generation
Power Electronics & Inverter Development and Test
Our development and test expertise includes inverters with voltages from 48V to 800V and various power ratings, IGBT, SiC, and GaN converters, and bidirectional AC-DC and DC-DC testing. We provide embedded control software development, conduct abnormal, desaturation, and double pulse testing, and optimise gate driver performance.
Test Rigs
UK:
- Dedicated HV Lab
- 1100 V DC Supply
- 1 x Control-HIL
- 1x EMC chamber
US:
- Dedicated HV Lab
- 1 x Control-HIL
- 1 x 400 kW Power-HIL (eMotor Emulator/EME)
Equipment
- 1GHz 8 channel scopes w/optical probes
- Multi channel power analysers
- HV lab and surface mount rework
- High power PSUs and battery emulators
- Logging / debugging / reflashing on rig
- C-HiL (control) and P-HIL (power) eMotor development rigs
- EMC chamber for pre-compliance testing
- Full DV testing with 3rd party facilities
Services
- Inverter development
- Pre-compliance testing
- EMC test & development
- DC-DC
- On-board charging
- Grid emulation
- High frequency scopes
- C-HIL P-HIL/EME eMotor Development
Learn more about Drive System Design’s EMC Chamber:
Sub-system & Component Development and Test
We offer versatile component and sub-system test rigs which support a range of activities, including development and validation processes. We also assist with technical studies and provide root cause analysis and resolution. Our bespoke rig designs and solutions-oriented approach ensure that we meet your specific needs.
Test Rigs
UK:
- 1 x 2E – 100kW 7000 RPM Cell
- 2 x 34 kW Spin & Tilt
- Various component and sub-system rigs
US:
- 1 x 50 kW 1E Motor Rig w/Tilt
- 1 x 160 kW 2E
Equipment
- Tilt test rigs – lubrication development
- Spin rigs – function, characterisation, optimisation and durability
- Bespoke test rigs – focused sub-system or component development activities
- Static loading
- Hydraulic sub-system
Services
- Lubrication development
- Park lock system
- Component durability
- Driveline disconnect
- Clutch testing
- Hydraulic systems
- Shift system testing
Prototyping & Build Facility
Our assembly team consists of highly skilled, experienced engineers and technicians. We operate in a flexible build environment, allowing us to adapt to the unique requirements of each project. We follow controlled build plans and maintain detailed assembly documentation.
Test Rigs
UK:
- 800 ft2 + Clean Build Room
- Inverter, Motor, EDU System build capability,
- Vehicle Hoist
US:
- 1,200 ft2 Clean Build Room
- Vehicle Hoist
- 6000 lb Build Stand and Gantry Crane
Equipment
- Bespoke assembly tooling designed in-house
- Large range of hand tools and equipment to permit controlled, fully documented assembly
- Metrology and inspection capability
- Rapid prototyping – 3D printing in house
- Fabrication and machining workshop
Services
- eMotor assembly
- Transmission assembly
- Differentials and bevel gears
- Hydraulics/mechatronics
- Inverter assembly
- Teardown and benchmarking
- Power electronics
Global Reach DSD has the facilities, equipment, automation, and expertise to be a trusted partner wherever you are based. We can tailor our testing services to your schedule and time zone, using highly automated test routines that operate 24/7, including complex inverter calibration processes. We offer responsive engineering teams, secure and fast data transfer and remote rig monitoring.
Want to understand how we can propel your business forward? Get in touch and one of our team will call you back.