Department of Mechanical Engineering

InterSyn advanced transmission research facility

PVRC Facilities transmission-researchThis test facility enables performance evaluation studies to be undertaken on a wide range of transmissions, including manual, automatic, auto-shift manual, and continuously/infinitely variable transmissions (CVTs/IVTs).

View or download the PVRC Advanced Transmission Research & Development leaflet [PDF].

The advanced transmission research facility features an ABB twin dyno and drive system arrangement capable of 109kW continuous rating.

The input and output machines are sized as follows to allow for the torque multiplication occurring in the transmission:

  • Input: 109kW ~ 500Nm 5500 rev/min
  • Output: rated to 200kW ~ 1kNm 4000 rev/min

The rig is configured for transmissions without integrated final drives, but those with final drives can be installed by the use of a step up transmission system.

The facility has access to a full range of HBM torque flanges available to target the torque capacity of test transmission (100, 500, 1000, 2000 Nm) and thus optimise the accuracy of recorded torque measurements.

Speed measurement is performed by highly accurate encoder system with 1024 pulse/rev allowing for pull away performance to be accurately investigated.

A CP Engineering systems integrated robot driver is available for automated shift programs or potentially for shift performance analysis.

The facility is connected to a fully populated CP Engineering Cadet V-12 control and data acquisition system, including 32 thermocouple channels, 16 off PRTs, multiple pressures and frequency measurement channels.

This allows for accurate recording of multiple data channels simultaneously. Additionally the Cadet system is able to record data off any powertrain/ transmission control module that communicates via CAN bus or on the ASAP3 protocol (given detail of the strategy).

Cadet Control system's experimental capabilities

  • Full Drive cycle emulation (NEDC, FTP75, HWFET, Japan 10-15 mode or any supplied)
  • Programming of customer defined performance schedules
  • Efficiency mapping
  • Shift control analysis
  • Oil and lubricant performance analysis

Additionally the control system has multiple safety features incorporated to protect valuable prototype transmissions from over torque/over speed/ over temperature scenarios.

Latest research developments aim to integrate the advanced transmission facility with our real-time engine modelling capabilities so that we can undertake Hardware-in-the-Loop testing of CVTs using virtual engine and vehicle models communicating with the dynamometer control system.