An auto manufacturer sought to expand its powertrain testing capability to support its future product development. While originally planned as an emissions calibration test cell, their product development plan moved towards electrification in the early stages of the project. Emissions systems were no longer in scope, and hybrid testing became the new focus.
The manufacturer required a test cell with a walk-in environmental chamber that could support extreme temperatures, ranging from -40° to 120°F. Temperature selection needed to be programmable in 5°F intervals, adding complexity. Key performance parameters remained undefined, creating ambiguity in design requirements.
ACS worked closely with the manufacturer to define performance criteria that balanced flexibility with budget constraints.
The challenge for ACS was to develop a test cell that could accommodate future requirements as the automaker expanded its powertrain product mix. The test cell had to be versatile enough to support combustion and electric testing while ensuring that performance criteria remained practical and achievable within budget and space constraints.
ACS designed and built a hybrid powertrain test cell for a combustion test and electric powertrain testing. The test cell features a two-motor test stand, with a walk-in environmental chamber encompassing the test article that supports testing at temperatures ranging from -40°F to 120°F. ACS oversaw the gutting of two smaller test cells and reconfiguring the space into a single hybrid powertrain test cell large enough to accommodate the new powertrain test system and environmental chamber.
A key challenge for the ACS teams was accommodating the new test cell equipment within the limited space. ACS worked closely with equipment vendors and internal design staff to ensure the new equipment was designed to fit within the existing space.
ACS installed a dedicated external refrigeration skid to maintain precise thermal control, relocating key components outside the hybrid test cell to free up valuable space. The project also required significant electrical upgrades to support the electric testing. Instead of extending power feeds from a remote substation—an expensive and time-consuming approach—ACS installed new switchgear closer to the test cell, improving efficiency and containing costs.
Working closely with the auto manufacturer, ACS integrated the client’s preferred data acquisition system into the test cell’s overall architecture, ensuring seamless compatibility with existing workflows and data management processes. This adaptability allowed ACS to meet the manufacturer’s specifications without disrupting their established testing methodologies.
By integrating these engineering solutions, ACS delivered a high-performance, future-ready hybrid powertrain test cell that allows the auto manufacturer to advance its varied powertrain solutions.
With ACS’ adaptability and engineering expertise, the auto manufacturer has a hybrid test cell capable of supporting its evolving powertrain development efforts. Originally planned as an emissions calibration cell, the ACS team facilitated a mid-project shift to accommodate a broader combustion test and electric powertrain testing—without compromising performance or cost efficiency. The ACS-designed test cell covers a wide operating range that meets immediate and future testing needs while including strategic cost-saving solutions.
A key factor in this success in providing the client with powertrain solutions was ACS’ ability to tailor its approach to meet the client’s broad needs while delivering an effective solution without overdesigning. Using the ACS flexible delivery model, the auto manufacturer was able to expand their original scope of work without unnecessary complexity. By balancing adaptability, technical expertise, and budget-conscious engineering, ACS delivered a high-performance hybrid powertrain test cell that will continue to support the client’s evolving development efforts.