Performance Test Dynamometer for E-Bikes Maturo GmbH designed the new unique dynamometer for performance testing of Pedelecs and E-Bikes based on new Standard EN 15194:2009 for EPACs (Electrically Power Assisted Cycles). Features: Four independently selectable drive units for front-/rear- and pedal-powered drive Speed up to 60 km/h, driving power up to 2000 W or more available Accurate readout and calculation of speed, torque and engine rating. Additionally, calibrated speed and torque sensors can be integrated in the system All results of the tests can be saved as a file and therefore can be used for a later documentation or analysis of the tests All measured values can be displayed in a characteristic curve in order to check the current results immediately Data collection of battery power and voltage as well as temperature with thermocouples Range determination of the batteries according to free programmable profiles with loop functions (uphill, downhill, headwind, friction, etc.) Sine-wave simulations of the pedalling motions of the pedals 1
Technical Data: Load capability Axle distance adjustable Tire diameter Different tyre width usable Speed adjustable between Speed accuracy 200 kg 750 to 1400 mm 26 to 29 inch 0 60 km/h +/- 0.1 km/h Current consumption max. 32 A Voltage 380-400 VAC, 50/60 Hz, 3-phase Control cable Duplex fibre optic cable Dimensions (L x B x H) approx. 2720 x 1450 x 935 mm Total weight approx. 500 kg Front and rear rollers drive: Diameter of rollers 150 mm Roller coating according road surface Rz 50 60µm Flame coated Motors Synchrony servo motors Rated maximum power max. 1200 W Rated maximum break-power max. 1200 W Permanently torque per wheel max. 50 Nm Pedal drive: Motors Synchrony servo motors Gear 40 Rated maximum power max. 2000 W Permanently torque incl. gear max. 480 Nm Velocity incl. gear max. 120 rpm Speed accuracy +/- 0.1 rpm 2
Basic functions of the systems: - Simulation of a sinus torque It is possible to simulate the cradle step of a person by using the two pedal drives. Permanent torque can also be selected as drive form. - Control strategy The system allows a selection of different control strategies both at the input value and at the output value, e.g. rhythmic cadence, power, torque. - Test driver mode It is also possible to use the dynamometer in test driver mode. In this mode the pedal drive are not in operation and the test vehicle is driven by a test driver. - Current-voltage characteristics It is possible to measure the current data s such as current and voltage by converter measurements. These values can be implemented both, in the data recording and in the higher level measurement software. - Temperature measurement Integrated thermocouples allow the measurement of temperatures at the Pedelecs. These values can be implemented both, in the data recording and in the higher level measurement software - Simulation of force A defined force at the axles of the wheels can be simulated by a mechanical construction. The force is evaluated by load cells and is implemented in the software. - Data recording All values of each measurement can be stored in a csv data base. All values can be stored with a recording time up to 1ms. - Communication It is possible to evaluate the current measured values with by higher level measurement software. There is an Ethernet interface available, which can be executed in different highlevel languages such as C, C++ or LabVIEW. In this case it is possible to have an individual control of each wheel. - Test Cycles Different types of test cycles can be created, stored and recalled. The single profiles can be executed several times with a loop function. One profile always includes the flow values (time or distance), the input control strategy (rhythmic cadence, power, and torque) as well as the output control strategy (power, torque, driving resistance). The different test cycles allows also the determination of the range. 3
Background: An EPAC (electrically power assisted cycles EPAC Bicycles) remains a bicycle without the necessity of a road traffic-legal approval, if: - the motor-driven support speed does not exceed 25 km/h - the motor-driven support is only activated, if there is also the pedal force / pedal movement activated - the motor output is maximum 250 W - the possible mode of a starting support does not exceed a maximum of 6 km/h, also at the mode without pedal movement The vehicle is liable to the European permission requirements for the road traffic (directives 2002/24/EG and 97/24/EG), if one of the above criteria is exceeding. Technical design of the system: - Adjustment of the wheel distance - Adjustment to the tyre and the rim width - Automatic calibration of the tyre diameter - Adjustment to the pedal crank (crank arm is removed) or direct fixing to the pedal crank - Velocity control - Torque control - Easy moveable by integrated wheels - Integrated safety PLC technology System options: - Automatic brake lever and start-up operation - Complete enclosure of the system due to local safety regulations - CAN interface for the reading out of data from the test vehicle or for operation of the support level and gear shift 4
Control by operating panel Technical Data: Data interfaces Transmission medium Transfer rate Display Ethernet CAT5 Real time 100 Mbit/s (fast Ethernet) 19 monitor Included in the control system are: - PC with integrated software - Keyboard, mouse and monitor - USB interface Updates easily implemented by USB stick Information presented enclosed is subject to change as product enhancements are made regularly. Pictures included are for illustration purposes only and do not represent all possible configurations. 5
maturo GmbH Am Kalvarienberg 24 o 92536 Pfreimd o Germany Web: www.maturo-gmbh.de Notes maturo GmbH 6