Set-up and Commissioning of advanced Test-Benches: Battery Emulator, High-Frequency Data Acquisition system and Oil Testing Methodologies

The transition toward future mobility is characterized by a progressive shift to electrified and high-efficiency solutions. This technological evolution creates new challenges for research and development, in particular the need for advanced, reliable, and adaptable testing methodologies capable of accurately simulating real operating conditions. Traditional test benches are usually dedicated to test a specific part of a component and are not able to capture the complex interactions between power-train components, energy management systems, and lubricants. Consequently, new testing infrastructures must be designed and commissioned to provide high-fidelity measurements, operational flexibility, and dedicated test methods that support both component and system-level evaluation. The main goal of this thesis is to describe the set-up and commissioning phases of a test-bench, and the overall process for developing new oil testing methodologies. The first two facilities, Test-bench 7.0 and Test-bench 6.2, integrate several key elements: a Battery Emulator, an Electric Axle (E-Axle), high-precision torque measurement devices, a dedicated cooling system for the Battery Emulator, and an independent cooling circuit for the Device Under Test (DUT). Data from these test-benches are acquired through a high-frequency data acquisition system, enabling precise tracking of transient phenomena and ensuring accurate characterization of power-train performance. These test-benches provide a versatile experimental platform that allows the investigation of energy flow, component efficiency, thermal management strategies, and system durability under a wide range of operational scenarios. The third facility ,Test-bench 6.1, is a back-to-back closed-circuit system incorporating two differentials. Unlike the previous ones, its primary focus is the evaluation of lubricant performance inside the differential through the development of different test-methodologies, those that are going to be conducted in this theses are: Thermal Gradient, Foaming and Efficiency tests. The overarching objective of the work is twofold: first, to describe and commission the functional setup of the three test benches, with a deep investigation of the main components; second, to analyze and develop suitable test methodologies that align with the company’s strategic goal of advancing oil performance evaluation. In summary, this work contributes to bridging the gap between laboratory testing and real-world operating conditions. A study of the operating principles, functional capabilities and intended applications was performed for Test benches 7.0 and 6.2. In addition, initial acceptance tests were carried out to verify their correct setup and commissioning. For Test-bench 6.1, building on studies conducted to understand the configuration setup and potential functionalities, the testing methodologies were developed and executed, yielding consistent and reliable results.