Flexible Powertrain Chassis Dynamometer

Hub-Mounted Chassis Dynamometer

with Steering Operation Capability

ROTOTEST Energy
Minimum Preparation Time and Reliable Repeatability
New Paradigm for “Road Load Simulation Testing” is here
MINIMUM INFRASTRUCTURE REQUIREMENTS
Compared with conventional roller-type chassis dynamometer
(CDM) (see figure 1), the ROTOTEST Energy system does not require
a large facility such as an underground pit. With a level floor plan
(e.g. garage) (see figure 2) and power (@400V, 3 phase) being the
main requirements, a full battery of tests can be carried out. The
dramatically lowers cost and provides flexibility.

Note: Additional equipment may be needed to support the

ROTOTEST test environment. This includes (but not limited to)
cooling and exhaust infrastructure.

Figure 1: Conventional Roller

Roller-Type
Type CDM

COST-EFFECTIVE
C

Figure
Fi
Figu
F
Fig
ig re 2
iigu 2:: RO
ROTOTEST
OTOTE
OT
O
OTE
TESST
T

EASY TO SETUP
E

SHORT SET UP TIME

When using other hub-mounted chassis dynamometers, it can take an inordinate of amount of preparation time to ready a
vehicle for testing. However with ROTOTEST, you can be ready for testing (see figure 3) in the same amount of time required to
install four common tires. Please note the set up time based on information from OEM’s and Engineering Consultants.

ROTOTEST
R
ROTOTE
TOTE
TE
ESST Energy
ST Ene
nerg
nerg
gy Competitors
Co m
Co mppe
ettittorrs
Se
S
Set
et u
upp tim
time
i e 10
1
10-15
0-1
-15
15 mi
m
minutes
inu
inu
ute
es 3-6
3-
-6 hour
ho
hours
ouurrs
rs

Time
T me
Ti remove
e to re
emo
m ve 10-15
1
10
0-1 minutes
15 mi
m inu
nute
tes
s 30-60
30
0-6 minutes
60 mi
m inu
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nutes
te
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Test
estt
Set-up
Set-
Set
Se
ett-
e t up Remove
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Rem
em
e ov
ove
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ve
Number
Numb
m err of
of operator(s)
operrat
op ator
tor
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(s 1-2
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1- 2-4
2-4
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Operation
Oper
Op
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ion ra
ion
io rate
ate per
te p day
err d
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y
ab
bou
out 86%
out
about 86%
86 ab
bou
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about 29
299%
% ROTOTEST
ROT TESTT Competitor
ROTO
ROT
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OT Compe
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eti
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Figure 3: Comparison of Set up and Operation Times

Please refer to the URL below to view a video on how to set up the ROTOTEST dynamometer.
https://www.toyo.co.jp/mecha/products/detail/ROTOTEST_Energy.html#link99

2
 ROTOTEST Hub-Coupled Chassis Dynamometer
Measurement System Real-time Distribution Controller
MODULE FOR VARIOUS TEST REQUIREMENTS
By utilizing a state of the art 4Q control system and
n – speed n – speed
the ROTOTEST Active Inertia technology, the vehicle’s
M - torque M - torque
inertia can be stimulated electronically to replicate true
road conditions. In addition to being able to simulate
different types of driving patterns, each tire can be
modeled using a “magic formula” (see figure 4).
Tire Model Vehicle Data
 Constant torque, constant speed
n – speed  Sweep
M - torque  Road load simulation
 Individual torque control, etc.
Figure 4
Fi 4: R
Real-time
l ti T
Torque Di
Distribution
t ib ti

STEERING OPERATION CAPABILITY

Due to its unique structure, ROTOTEST Energy
EXPANDABLE TEST MODULE
E provides a bench test with steering operations. This is
something not typically achievable with conventional
CDM. The steering angle can be rotated to +/- 20
degrees (see figure 5).

You can simulate driving situations including steering

operation, evaluate for ADAS, autonomous car, etc.
ROTOTEST Energy will take you to new levels on the
bench test.

STEERING OPERATION

CRITICAL
C MEASUREMENTS
Figure 5: Steering Controls

MEASUREMENT SYSTEM WITH HIGH ACCURACY AND REPEATABILITY

When it comes to CDM, measuring torque directly in the hub position brings many advantages including high accuracy and
constant repeatability. With no interference (see figure 6) from the automobile’s tires, this system achieves high repeatability,
which is important for performing benchmark testing. In addition, this unit can be automatically tilted in order to adjust the
torque measurement line. Also see figures 7 and 8.

Powertrain Direct
Dynamometer
Chassis Coupling

Power consumption
measurement of headlight
(@ 30km/h, low / high beam)

Figure
Figu
gure
gu re 6 Figures 7 & 8

3
ROTOTEST Standard
Model

500 KW - 250 KW MODEL FOR ROAD LOAD

SIMULATION
ROTOTEST Energy 500-250 4WD consists of each 500 kW,
250 kW dynamometer axle. It can be used for 4WD and
2WD depending on the vehicle under test. See figure 9
which shows a ROTOTEST unit mounted on an automobile.
Because of its repeatability, accurate results can be
obtained from the benchmark test. Several power models
are available depending on your specified requirements.

APPLICATION EXAMPLE: INDIVIDUAL

WHEEL TORQUE CONTROL
You can control each wheel’s torque individually
with the dynamometers connected directly to each
wheel. The left graph below (see figure 10) shows
the torque distribution when all tires except the Figure 9: ROTOTEST Unit Mounted on Front Driver Side
front left one drives on a snow covered road. The
right graph below (see figure 11) represents the
situation when turning the steering wheel.

Figure 10: Torque Distribution in Snow Covered Road Scenario Figure 11: Torque Distribution during Steering

By defining a vehicle’s mass and  of each

tire, the running resistance can be simulated
(see figure 12).

For example, the condition where some

specific tires are on different road
conditions can be simulated.

Figure 12: Running Resistance Simulation

4
ROTOTEST Climate
Model ROTOTEST Hub-Coupled Chassis Dynamometer

BUILT-IN CLIMATE PROTECTION (CP) MODEL (-31° TO 105° F; -35° TO 40° C)

This model has an expanded operational temperature range of -31° to 105° Fahrenheit (-35° to 40° Celsius). Given sufficient
space, this system can be used in an already existing climate chamber. You may evaluate a vehicle’s behavior in a cold
region including steering operation (see figure 13).

APPLICATION EXAMPLE: ENERGY

FLOW MANAGEMENT EVALUATION
This graph on the right (see figure 12) shows
power consumption for an air conditioner.
Running a gasoline engine at 1,500 rpm, “A/C
power consumption” + “generator loss” can
be measured as a power difference. Due to
accurate torque measurements with the hub
mounted ROTOTEST Energy, energy flows can
be characterized accurately.

Figure 13: Power Consumption with Air Conditioner On

5
ROTOTEST NVH
Model

LOW NOISE MODEL FOR NOISE, VIBRATION, AND HARSHNESS (NVH) TEST
Even very low noise levels can negatively impact NVH measurements. Compared with traditional roller type dynamometers,
there is next to no tire noise generated by the ROTOTEST units.

ROTOTEST Energy NVH can be customized by removing blowers for cooling and covered with sound insulation boxes. The
model can also be installed in semi-anechoic chambers.

APPLICATION EXAMPLE: NVH TEST

Operational noise driving at 100 km/h is only Overall Noise
about 45 dBA. Therefore you can evaluate NVH
phenomena which are usually buried in noise Tire Noise
coming from tires. In addition, there is no need
to bind the vehicle. So it is possible to minimize
A Weighting Level (dBA)

changes to the NVH character due to binding.

Refer to figure 14.

Examples include: IC Noise

 Evaluating noise from EPS

 Precise noise measurement (intake
/ exhaust, powertrain, etc.)
 Contribution analysis in indoor
ROTOTEST
is less than
45 dBA
even
@100 km/h
Vehicle Speed (km/h)

Figure 14: Relationship between Noise and Speed

6
 ROTOTEST Hub-Coupled Chassis Dynamometer
SPECIFICATIONS
Each system consists of dynamometers (2WD or 4WD), SCU, and MPU. The SCU is a system control unit, while MPU is the
main power unit of each dynamometer.

GENERAL SPECIFICATIONS
Torque uncertainty < 1% of measured value
Speed uncertainty 0.1 rpm
Repeatability < 0.05%
Inertia 0.6 kg  m2 (300 kW unit)
Maximum axle load 3,500 kg
Temperature range +59° to +104° F; +15 to +40 C (except climate
model)
Humidity 10-90%, non-condensing
Altitude < 1,000 m above sea level
Power (SCU) 240 VAC (8A) or 120 VAC (16A) @ single phase
Power (MPU) 400 VAC, 50 / 60 Hz @ 3 phase
Cooling method Air Cooling

STANDARD MODEL
System ROTOTEST Energy 500-250 4WD
Component 1 axle of RE-500 (Dyno), 1 axle of RE-250 (Dyno),
MPU-500×2, MPU-250×2, SCU-4E×1
Power† 2WD 500 kW/400 kW (momentary/continuous)
Power† 4WD (50/50 split) 500 kW/400 kW (momentary/continuous)
Torque 2WD 6,000 Nm/2,550 Nm (momentary/continuous)
Torque 4WD (50/50 split) 5,960 Nm/2,450 Nm (momentary/continuous)
Spee
p
Speed 2WD/4WD 2,700 rpm (maximum hub speed)
Vehicle Speed 2WD/4WD
Vehi 330 km/h (equivalent, wheel dia 650 mm)

CLIM
CLIMATE MODEL
Syst
y
System ROTOTEST Energy 230-CP 4WD
Component
Com 2 axles of RE-230-CP (Dyno), MPU-230CP x 4,
SCU-4E x 1
Pow † 2WD
Power 230 kW/120 kW (momentary/continuous)
Power† 4WD (50/50 split)
Pow 460 kW/240 kW (momentary/continuous)
Torq
q
Torque 2WD 2,800Nm/1,200 Nm (momentary/continuous)
Torq
q
Torque 4WD (50/50 split) 5,600 Nm/2,400 Nm (momentary/continuous)
Spee
p
Speed 2WD/4WD 2,500 rpm (maximum hub speed)
Vehicle
V
Veh i Speed 2WD/4WD 300 km/h (equivalent, wheel dia 650 mm)
Environment
Envi -31° to 105° F (-35° to 40° C) | 10-95% (humidity), (non-condensing)
IP54

NVH MODEL
Syst
y
System ROTOTEST Energy 300-NVH 4WD
Component
Com 2 axles of RE-300-NVH (Dyno), MPU-300 x 4,
SCU-4E x 1
Pow † 2WD
Power 300 kW (5 min‡)
Pow † ‡
Power 4WD (50/50 split) 600 kW (5 min )
Torq
Torque 2WD 2,980 Nm
Torque 4WD (50/50 split) 5,960 Nm
Speed 2WD/4WD 3,000 rpm (maximum hub speed)
Vehicle Speed 2WD/4WD 360 km/h (equivalent, wheel dia 650 mm)
Noise less than 45 dBA
† at 68° F (20° C)
‡ defined as a 5 minute run / 30 minute cool down

7
 ABOUT ROTOTEST INTERNATIONAL AB
Founded in January 1988, Rototest was established by a group of engineers with solid experience
in product development in the vehicle industry. After a few years, devoted to intense development
and testing, Rototest pioneered the market by introducing the world’s first hub-coupled
dynamometer. The company is based in Sweden.

Rototest test solutions is today used by many of the world’s renowned industrial companies in
more than 25 countries across North America, Europe, Asia and Africa.

ABOUT TOYO CORPORATION

TOYO is committed to providing the
automobile industry with leading edge
test and measurement solutions,
and we maintain a fully staffed and
functioning technical research lab in
Atsugi, Japan.

The lab is equipped with the latest

ROTOTEST Energy systems. The
lab also serves as a demonstration
facility where customers interested
in the solution can see ROTOTEST
test systems in operation. TOYO is a
partner of Rototest.

42840 Christy Street, Suite 110, Fremont, CA 94538

Phone: 510-438-9548 | E-mail: info@toyotechus.com © Copyright 2018 TOYOTech. All rights reserved. All trademarks used in this document are the property
of their respective owners. TOYOTech reserves the right to change product content and product
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06/26/2018 (SCW)