Kistler redefines E-Powertrain Analysis for Electric and Hybrid Drives

With real-time power analysis, ultra-fast calculation windows even for highly dynamic and precise testing procedures, and a modular design that scales to virtually any application, the KiBox2 E-Powertrain Analysis sets a new standard for e-drive testing.

From the dynamometer to the test track, KiBox2 E-Powertrain Analysis is built to support engineers at every stage, from system integration and calibration to optimisation and limit testing. It measures individual drive components like power electronics, inverters, e-motors, and resolvers, and handles complete component assemblies just as easily. Direct or alternating current, high- or low-voltage measurement, or the analysis of energy management systems - KiBox2 covers the entire range in one single tool.

The scalable system with up to 64 measuring channels and powerful processing functions records the necessary measurement signals across the entire powertrain. These signals are then processed immediately via dedicated software solutions - a clear advantage over standard DAQ systems. Developers instantly receive detailed, real-time visualisation and analysis of application-specific e-machine data. On top of that, the system measures and processes specific measurement currents from current transducers, which are primarily used in high-voltage applications, plus signals from standard current clamps.

Under the hood: what makes KiBox2 tick

The KiBox2 E-Powertrain Analysis brings together three compact, high-performance components for data acquisition and power analysis of electric powertrains. The 16-channel measuring unit works as a compact, mobile power analyser for real-time measurement, calculation, and visualisation with rapid processing of 2.5 MS/s per channel.

The HVAQ 4-channel high-voltage module is an electrically isolated voltage module with a measuring range of up to +/-1000 Vrms / +/-1500 Vpeak. It reaches the safety level of 1000V CAT II / 600V CAT III. Completing the trio, the HCAQ 4-channel high-current module pushes current measuring ranges of up to 2000 A via the Current Conditioner Box, with full support for external zero-flux current transducers as well.

Versatile, precise, robust, compatible and effective

KiBox2 performs both in the lab and in the field. Designed to integrate seamlessly into test stand automation systems, its compact, robust design makes it just as capable in the vehicle as it is on the bench. On-track vehicle testing requires unique hardware capabilities, which the KiBox2 E-Powertrain Analysis can deliver. It handles strong vibrations and can be connected to the vehicle's power supply. Its powerful electrical power analyser allows for precise measurement and calculation of electrical power flows and losses with high-resolution data storage for detailed offline analysis whenever you need it.

The intuitive user interface enables a fast and straightforward start. The advanced signal conditioning simplifies the analysis of electric power, making it possible to quickly identify losses. The intelligent algorithm ensures precise real-time cycle detection and can be flexibly configured up to one-quarter of an electrical cycle. All data is saved in an ASAM-compatible format (.mdf). For custom workflow integration, a corresponding converter can be used to output alternative data formats.

A power analyser for cross-platform power analysis

Power analysis of electric powertrains and combustion-based technologies, such as range extenders, can be carried out simultaneously with a single system. Synchronized data acquisition and calculation of crank-angle and time-based measurands allows for combined energy flow analysis in both domains. in addition, mechanical torque systems can be directly connected to KiBox2 via analogue or digital inputs. By including physical parameters like speed and torque, KiBox2 expands its range of applications to include mechanical power analysis as well.

Vehicle efficiency has always been a key concern, even before electric and hybrid drives became widespread. By combining measurements and analysis of electric and combustion drives as well as recording mechanical signals from torque systems, Kistler equips R&D teams with a system that's ready for any direction the industry takes. To keep up with that versatility on the software side, Kistler has expanded its Cockpit software solution with the newly developed "E-Powertrain" application module. Kistler's jBEAM Powertrain software is ideal for the further processing of data.