Electric drive systems are rapidly evolving toward highly integrated 3-in-1 and X-in-1 architectures. While these designs improve space utilization and cost efficiency, they also place higher demands on system reliability validation. Key challenges include operation under high thermal loads, stability in extreme environments, and the energy consumption and data management burdens associated with long-duration endurance testing.

The Chroma 1220 E-Axle Test System addresses these challenges with a comprehensive validation solution. A leading Vietnamese automaker recently deployed the Chroma 1220 B2B (back-to-back) configuration for long-duration endurance testing with integrated environmental simulation, enabling its engineering team to closely replicate real-world driving conditions.

▲Chroma 1220 B2B E-Axle Endurance Testing with Integrated Environmental Chamber

Energy Recovery and System Efficiency Optimization

In the Chroma 1220 B2B test configuration, two devices under test (DUTs), such as two e-drive systems, are coupled on the mechanical side via a 1:1 speed-matched transmission, while energy recirculation is achieved on the electrical side through a shared DC bus. This architecture not only enables efficient recovery of test energy, but also significantly reduces the required power rating of the DC power supply (acting as a battery simulator). Key benefits include:

• Reduced Power Requirement: The DC source no longer needs to supply the full test power throughout the entire load cycle, but only compensates for overall conversion losses.
• Lower Equipment Cost: Battery simulator capacity requirements can be reduced by approximately 40–50%.
• Optimized Operating Costs: Reduces both contracted power capacity and overall laboratory operating expenses.

Integrated Environmental Simulation and Thermal Management Validation

The back-to-back setup integrates an environmental chamber, water chiller, and flow control unit to precisely regulate temperature, humidity, and other cooling conditions. This enables the simulation of e-drive system behavior under various extreme operating conditions and supports multiple critical test cases, including:

• Energy consumption and efficiency analysis: Consumption and efficiency changes under WLTP and other driving cycles
• Reliability validation: Thermal degradation and reliability validation under high/low temperature cycling
• Safety mechanisms: Validation of protection strategies under abnormal cooling flow conditions

By synchronizing environmental simulation with dynamic load control, the system closely replicates real vehicle operating conditions and substantially accelerates development and validation processes.

▲WLTP Testing and Integrated Chamber/Chiller Thermal Management Data

Automated Testing and Data Analysis Capabilities

The system supports long-duration automated testing. Through a graphical interface and script-based configuration, users can create multiple test conditions and execute them continuously.

• Safety Mechanisms : Automatic protection and fault-trigger mechanisms
• Multi-Dimensional Data Integration: Comprehensive analysis of speed, torque, temperature, and electrical data
• Automated output: Efficiency maps and automated report generation

These capabilities significantly enhance data analysis efficiency and accelerate development workflows.

Standardized Specifications with Comprehensive Customization

Built on the standard architecture of Chroma 1220 E-Axle Test System, the test environment can be customized to meet specific DUT requirements, including mechanical configuration and thermal management integration.
Reference specifications include:

• Maximum speed: 0 – 3,300 rpm
• Peak torque: 0 – 2,984 Nm
• Rated power: 250 kW

From HIL (Hardware-in-the-Loop) dynamic simulation and back-to-back endurance testing to integrated validation under extreme environmental conditions, the Chroma 1220 B2B test system provides a comprehensive and efficient solution for e-drive testing. Looking ahead, Chroma will continue to advance its testing technologies and system integration capabilities, helping global automakers and supply chain partners accelerate the development of next-generation EV technologies.

For more product information, please visit the Chroma website and leave your requirements and contact details. Our team is dedicated to providing you with the best possible support.