The simulation cycling test bench is used for DC brushless mid-mounted motors and DC brushless hub motors, meeting the type test requirements for motors with a torque of up to 200 N.m and an input pow ...
The simulation cycling test bench is used for DC brushless mid-mounted motors and DC brushless hub motors, meeting the type test requirements for motors with a torque of up to 200 N.m and an input power of up to 1.8 kW. It adopts a two-stage torque sensor, with a direct drive torque range of 200 N.m and a transmission torque range of 50 N.m.
Core Functions
1. Power Performance Testing
Top Speed: Supports dynamic adjustment from 0 to 80 km/h, simulating driving resistance through rollers to verify motor output power and efficiency.
Acceleration Performance: Allows setting of 20 torque points (0-1000 kg-cm), generating torque-speed curves to analyze transmission efficiency.
Climbing Ability: Adjusts slope from 0 to 25% using a hydraulic lifting device, and simulates load resistance with a magnetic powder brake to test vehicle climbing torque.
2. Brake Safety Inspection
Dry/Wet Braking: Equipped with a spray system (flow rate 5 ml/s), measures dry braking distance (≤4 m), wet braking distance (≤15 m), and records stopping time and deceleration.
Emergency Brake Trigger: Supports triggering by pedal force (0-1000 N) or handbrake force (0-500 N), and monitors brake coordination time and average deceleration in real time.
3. Road Condition Simulation and Durability Testing
Roller Road Conditions: Dual rollers with a diameter of 760 mm (±10 mm), and the surface can be equipped with impact blocks to simulate bumpy and potholed roads.
Continuous Riding Test: Supports 0-999,999 cycle loading, simulating the fatigue resistance of the frame and suspension system after long-term use.
4. Energy Consumption and Range Evaluation
Battery Performance: Monitors battery input voltage (0-600 V), current (0-2 A), and power, calculating energy consumption per 100 km (≤1.2 kWh) and range.
Energy Efficiency Curve: Records energy consumption rate through a US NI acquisition card, and plots the speed-energy consumption relationship graph.
Technical parameters:
| Parameter | Specification |
|---|---|
| Motor voltage measurement (electrical parameter test) during operation | DC 0-100V |
| Voltage range | 0.1% |
| Measurement accuracy | 0.01V |
| Display resolution | (Same as GNL JXK-10-SGN) |
| Test current | -10°C to 50°C |
| Current range | -10°C to 50°C |
| Measurement accuracy | 0.5% |
| Display resolution | 10 mA |
| Power measurement | Motor power calculated from voltage and current feedback via sensors |
| DC regulated switching power supply (Meiensi) | DC 0-80V / 75A (Programmable, with voltage compensation function) |
Application scenarios
1.Bicycle/Electric Bicycle Whole Vehicle Testing
Test items: Maximum speed, acceleration performance, climbing ability, range (constant speed method/condition method), braking distance, coasting distance, pedal force-speed characteristics (electric-assisted bicycle).
Applicable objects: mountain bikes, road bikes, city commuter bikes, shared bikes, electric bikes, electric scooters.
2. Motorcycle/Fuel-assisted Vehicle Testing
Test items: Chassis power test (wheel-end power), constant speed fuel consumption, working condition method emissions (CO, HC, NOx), acceleration performance, maximum speed, braking performance, durability and reliability.
Applicable objects: Scooters, motorcycles, three-wheeled motorcycles, and ATVs (All-Terrain Vehicles).
3. Motor and Controller Performance Testing
Test items: Motor external characteristic curve (torque - speed - power), efficiency MAP diagram, overload capacity, temperature rise characteristics, controller current limiting protection characteristics.
Applicable objects: hub motors, mid-mounted motors, permanent magnet synchronous motors, and brushless DC motors.
4. Battery System Testing
Test items: Discharge performance under different working conditions (voltage platform, discharge capacity), battery temperature rise, energy recovery efficiency, and verification of SOC estimation accuracy.
Applicable objects: Lead-acid batteries, lithium batteries, hydrogen fuel cells (with corresponding loads).
5. Brake System Testing
Test items: Deceleration during braking, braking distance, force balance between front and rear wheels, brake fade performance, and evaluation of ABS and brake assist effects.
Applicable objects: Disc brake system, drum brake system, hydraulic braking, and by-wire braking.
6. Durability and Reliability Testing
Test Scheme: Based on the measured road load spectrum, an intensified durability test program is developed. The test runs continuously for 24 hours to assess the fatigue life of components such as the frame, transmission system, motor, and battery.
Applicable objects: Vehicle reliability verification, component durability certification.
Selection Guide: How to Choose the Right Cycling Simulator Test Stand for You?
1. Select by the type of vehicle being tested
Lightweight (bicycles/electric bicycles): Maximum power ≤ 5 kW, maximum speed ≤ 60 km/h, basic or standard type can be chosen.
Medium-sized (scooter/motorcycle with small displacement): Maximum power ≤ 20 kW, maximum speed ≤ 120 km/h. It is recommended to choose standard type or professional type.
Heavy-duty (large-displacement motorcycles/tricycles): Maximum power ≤ 50 kW or higher, maximum speed ≥ 160 km/h, custom heavy-duty models are required.
2. Select according to test standards
National standard tests: It is necessary to confirm whether the test bench meets the requirements of standards such as GB/T 24157 (Electric bicycle mileage test), GB 7258 (Safety operation conditions for motor vehicles), and GB 14622 (Emission standards for motorcycles).
International standards: If there is an export requirement, it is necessary to meet standards such as ISO 4210 (Bicycle Safety), ECE R40 (Motorcycle Emissions), DIN 79000 (Power-assisted Bicycles), etc. The test bench software should have the corresponding working conditions built in.
3. Selecting Models Based on Test Functions
Function Module Applicable Scenarios Recommended Configuration
Power/Economy Testing Performance assessment in the early stage of R&D, application for qualification certificates Basic model + Torque/Speed sensors
Brake Performance Testing Brake system development, ABS matching Basic model + Force sensors, Displacement sensors
Durability Testing Reliability verification, life assessment Basic model + Enhanced durability program, 24-hour continuous operation capability
Vibration/Noise Testing Comfort optimization, abnormal noise investigation Professional model + Vibration sensors, Acoustic test interface
Environmental Simulation Verification of adaptability to high/low temperatures and humidity Professional model + Environmental chamber integration interface
