Automobie Testing Systems
- In-Tyre-House Dynamo® (ITHD®)
- Testing System
- Dynamometer
- Machine Control and Measurement Operation
- Control and Measurement Operation
- Battery Simulator
At Toyo Denki, we support the development of next-generation vehicles with a testing system consisting of industry-leading high-performance motors and inverters.
- In addition to the motor drive technology we have cultivated over many years, we offer a comprehensive system that also includes machinery and measurement operation.
- We support the development of next-generation vehicles by shortening the development period with high accuracy and reliability.
- In addition to incorporating drive technologies unique to motor manufacturers, Toyo Denki's proprietary technologies include mechanical systems and measurement operation panels designed for ease-of-use and safety.
Catalog: Automobie Testing Systems（1.6MB）
In-Tyre-House Dynamo® (ITHD®)
ITHD was developed to evaluate autonomous vehicles expected to become popular in the future, and as a substitute for chassis dynamometers. In addition to enhancing our product lineup, we will continue to refine this product and develop it as a new device.
Features
Space-Saving
ITHD does not require large-scale construction work normally associated with conventional chassis dynamometers, and can be installed anywhere there is a space with flat surface. Furthermore, minimal floor work is involved, and there is no need for additional pit work or surface plate installation. It can also be installed in anechoic chambers and environmental chambers.
Driving Test Verification
Testing equivalent to that using a chassis dynamometer is possible, and the four wheels can be individually controlled to simulate various driving conditions.
Quietness
The dynamo achieves a noise level of approximately 70 dB. Vehicle noise can be checked clearly even while driving. In addition, since this system has no tires, there is no road noise, making it possible to distinguish noise inside the vehicle.
Installation
ITHD can be installed by replacing the wheels using a floor jack. The system is compatible with all hub shapes using a dedicated adapter. The camber angle, caster angle, toe-in, and toe-out are of the same structure as the actual car. Furthermore, there are no vehicle wheelbase restrictions, meaning that it can be used for various types of vehicles.
Future Potential
ITHD can be used for the evaluation of autonomous vehicles by combining it with vehicle cameras, radar, and GPS. In addition, verification that was previously only possible on test courses or actual roads can be performed safely on the platform.
Specifications
| Rated capacity | 94.2kW | 160kW |
|---|---|---|
| Max. rotation speed | 2,000min-1 | 2,500min-1 |
| Max. instantaneous torque | 1,350Nm | 3,800Nm |
| Equipment exterior (diameter) | 650mm | 680mm |
| Tread width (dynamo body) | 185mm | 340mm |
| Compatible brakes (diameter) | Up to 425 mm | Up to 460 mm |
Introduction to Toyo Denki Seizo In-Tyre-House Dynamo®（ITHD®）
Toyo Denki Seizo In-Tyre-House Dynamo®（ITHD®）Installation Method
Testing System
Toyo Denki helps shorten the product development period and improve reliability by contributing to the evaluation of the various automobile components such as the drive system (transmission, etc.) and engine.
Features
- Engine behavior is reproduced with a dynamo boasting industry-leading levels of low inertia.
- The equipment configuration is tailored to customer ease-of-use and the features of the test-piece.
- Control and measurement operation system designed to the meet customer requirements.
- Compact system reduces installation space.
- Compatible with EV and HEV testing.
[Test application examples]
Endurance test/performance test/efficiency test/noise, vibration test/sensory test, etc.
[Examples of applicable test pieces]
FF units (M/T, A/T, CVT, HEV)/FR units (M/T, A/T, CVT, HEV)/transfers/differential gears/engines, etc.
Evaluation Pattern Example
Dynamometer
As a motor manufacturer with long history approaching 100 years, Toyo Denki was among the first to introduce permanent magnet synchronous motors to the world. The Dynamic Spin Dynamo - DSD Series employs a unique water-cooling system for this permanent magnet synchronous motor.
Low-Inertia Motor DSD (Dynamic Spin Dynamo) Series
Industry-Leading Low Inertia
The Dynamic Spin Dynamo - DSD Series achieves industry-leading levels of low inertia, and the moment of inertia is reduced to around 1/10 that of induction motors of same capacity.
Toyo Denki's Proprietary Water-Cooling System Significantly Reduces Motor Size Over Conventional Motors
Toyo Denki's proprietary water-cooling system significantly reduces motor size over conventional motors.
Frame Structure Designed to Test Limits
In addition to making the testing system compact, the frame structure has been designed to maximize the distance between the shaft and the drive shaft to achieve a layout equivalent to that of an actual vehicle. Furthermore, it is astonishingly quiet, and also suitable for NV benches.
High-Speed Torque Response
A new current control system has been adopted to achieve high-speed current calculation and vector control calculation output, and a torque response of 1,500 Hz or higher has been realized.
Achievement of a Max. Output Frequency of 1,500 Hz (Special Spec. Product)
As a vector-control inverter, an output frequency of 1,500 Hz has been realized, and a maximum rotation speed of 20,000 min-1 has been achieved in combination with a 6-pole S-DSD Series motor.
Product List
High-Speed, Low-Inertia Dynamometer: S-DSD, S-DSDi, S-DSD HP, S2-DSD
| Output | Up to 505 kW |
|---|---|
| Rotation speed | Up to 10,000min-1 |
| Torque (max.) | Up to 1,610Nm max |
Ultra-High-Speed, Low-Inertia Dynamometer: S-DSD HS
| Output | Up to 220 kW |
|---|---|
| Rotation speed | *Up to 20,000 kW-1 |
| Torque (max.) | Up to 525Nm max |
(*) Please inquire separately for rotation speeds exceeding 16,000 min-1
High-Torque, Low-Inertia Dynamometer: H-DSD, W-DSD
| Output | Up to 535 kW |
|---|---|
| Rotation speed | Up to 4,000 mi-1 |
| Torque (max.) | Up to 5,960Nm max |
Machinery
Features
Equipment Configuration Tailored to Features of Test Piece
FF transmission ↔ FF transmission/FF transferMotor drive ↔ engine drive
Bench Configuration that Takes Advantage of Features (Compact, Lightweight) of Special Dynamometer for Testing Equipment (DSD)
Bench configuration that takes advantage of features (compact, lightweight) of special dynamometer for testing equipment (DSD)Compact
bench - configuration that takes advantage of small diameter Inclined
bench - configuration that takes advantage of light weight
Machine Control and Measurement Operation
Select the control controller based on the system required.
Features
- Equipped with data display with analog meter, digital panel, and trend graphs, etc.
- The data display can be placed by the user in the desired location, and the size can be adjusted freely.
- Multiple measurement pages make it easy to change the display configuration when changing measurement conditions.
- Equipped with two-stage alarm function for warnings and faults for each measurement item.
- The color of the analog meter and analog bar can be changed for each stage, making it easy to check setting values.
Control Application
Control type
- Speed control
- Torque control
- Throttle opening control
- Adaptive speed control
- Electric inertia control + running resistance
- Absorption side servo lock control
- Sine wave excitation control
- Arbitrary engine firing variation
- Damping control
- Torque down control
- Bumpless function
Examples
Sine wave excitation control
The primary frequency of the engine can be reproduced.
Arbitrary Engine Firing Variation Excitation Control
Engine firing can be reproduced from the primary to 5th order frequency.
Damping control
Equipment resonance can be suppressed.
Battery Simulator
This battery simulator is capable of simulating large-capacity batteries with maximum output voltage of 1,000 V and maximum output current of 2,000 A, and is capable of power circulation when combined with Toyo Denki's dynamo.
System Configuration
Power circulation is possible in combination with Toyo Denki's dynamo.
Control Mode
| Basic control | Constant voltage mode |
|---|---|
| System upgrade | Constant current mode Constant power mode BTS mode (simulates resistance inside battery) |
Basic Specifications
| Output Voltage | 100 to 1,000 V (operating range: 50 to 1,000 V) | |||
|---|---|---|---|---|
| Rated current | 48 to 2,000 A | |||
| Control accuracy | Control Mode | Constant voltage mode | Constant current mode | Constant output mode |
| Control accuracy* | ±１V | ±3％FS | ±5％FS | |
| Response time* | 30ms | 10ms | 150ms | |
*Please inquire separately about the control accuracy and response time.
Product Inquiries