Testing Services

Testing and Verification from One Source by Magna Powertrain Engineering Center Steyr

Magna boasts a robust infrastructure designed to cover the entire development chain, including testing from the complete system level down to the individual component level.

Our success lies in our ability to simulate and test according to global standards. The full range of virtual and real development tests are performed in-house, enabling us to offer high process quality and a wide array of services, including component release.

Our leading testing facility in St. Valentin, Austria, is a full-service provider and proving ground for functional and endurance testing. It features fully automated engine and powertrain test benches for both conventional and alternative systems, a fatigue laboratory, and a state-of-the-art four-wheel drive (4WD) chassis dynamometer for functional, NVH, and emissions optimization for complete vehicles.

Gearbox & eDrive Testing

Main Development Topics
  • Component testing
  • System and functional testing
  • Benchmarks
  • Durability tests
  • Efficiency analysis
  • High dynamic tilting tests
Highlighted Specifications
  • Gearbox input speed < 20,000 rpm
  • Power up to 800 kW for each test bench dyno
  • Wheel torque up to 60,000 Nm
  • Battery simulator up to 1,2 MW
  • Environmental conditions (water, oil and environment)
  • Wide range of applications: passenger car, light and heavy duty trucks, nonroad, ...
  • Complete driveline testing up to 6 machines at one setup
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

Environmental Inverter & EMC Testing

Environmental Testing eDS, Inverter & eMotor
  • Climatic
  • Mechanic
  • Lifetime
  • Application related
Inverter Testing
  • Functional testing of inverter and subcomponents
  • Thermal verification
  • EoL testing
EMC Testing
  • Emission
  • Immunity
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

Engine Test Benches

Main Development Topics
  • Dynamic and steady state testing
  • Function and durability testing
  • Engine and OBD calibration
  • Exhaust gas after treatment calibration and development
  • Component testing
  • Engine benchmark
  • Engine homologation
  • Frictional power analysis
Specification & Supported Engines
  • Compression and sparked ignition engines, 48V & HV hybrid systems
  • Power range: up to max. 520 kW mechanical, up to < 600kW electrical
  • Field of applications: passenger car, light and heavy duty trucks, nonroad, ...
Measurement Equipment
  • AVL FTIR / IAG FTIR
  • AVL Micro Soot
  • AVL Particle Counter
  • AVL Opacimeter
  • AVL Coriolis
  • AVL Indicating System
  • AVL Flow Sonix
Testing equipment in a manufacturing facility

High Altitude & Climate Test Bench

Rear view of grey vehicle taillights on with fog in background

Test Chamber

  • Max. altitude 5000 m (540 mbar)
  • Performance 500 kW
  • Torque 2600 Nm / 3100 Nm peak
  • Max. speed 8000 U/min
  • Temperature -25°C / +50°C
  • Electrical power supply

Fatigue Laboratory / Fatigue Testing

Equipment & Infrastructure
  • 250 servo-hydraulic actuators
  • Forces between 10 kN - 500 kN
  • Frequency up to 100 Hz
  • Up to 40 actuators can be controlled simultaneously
  • Max. weight of specimen: 50 tons
Main Testing Topics
  • Cabin / body
  • Axle and suspension
  • Add on parts and components
  • Frame and subframe
  • Steering system
  • Determine material properties
  • Material testing (high T)
  • Testing under corrosion
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

4WD Chassis Dynamometer

Main Development Topics
  • Acoustics and vibrations
  • Energy and thermal management
  • Functional development
  • Emission measurement
Specification
  • 4 single wheel drives: 4 x 250 kW
  • Maximum vehicle speed: 260 km/h
  • Max. drag force: 12,000 N/axle
  • Flexible wheelbase from: 2.0 4.4 m
  • Vertical load per axle: 4,500 kg
Wind Tunnel
  • Airflow: 140,000 m3/h
  • Variable outlet: 0.54 ... 1.8 m2
  • Temperature condition: -20°C up to +50°C
NVH Test Cell
  • Free field from: 40 Hz to 10 KHz
  • Cell dimensions (l x b x h): 12 x 8.3 x 4.5 m
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

Battery Cell Testing

Test Configurations
  • Electrical characterization (performance, capacity, inner resistence)
  • Thermal performance characterization
  • Aging and lifetime
  • Engineering development of electrothermal cell models
Temperature Chamber
  • -40°C to +90°C
  • 5 K/min
  • 4500 W heat compensation
  • 1000 l
  • Safety: HL5
Cell Cycle
  • 0 - 5 V
  • 12 channels a 50 A
  • 4 channels a 600 A
  • Parallelization up to 2400 A
  • ± 0.01% @ current
  • ± 0.025% @ voltage
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

Driveline Testing

Functional Testing
  • Lubrication and ventilation testing
  • Bearing adjustment
  • Contact pattern
  • Shifting of gears
  • Engagement of locks
  • Clutch characteristics
  • Temperature behavior loaded
  • Efficiency measurement
  • NVH measurements
Durability Testing
  • Gears, bearings
  • Differential
  • Seal rings
  • AWD clutch
  • Actuation system
  • Park lock
Ultimate Strength Testing
  • Static ultimate strength testing
  • Dynamic ultimate strength testing
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

Thermal System Testing

Thermal System Tests Bench
  • Validation up to complete vehicle thermal systems (HVAC, refrigerant and coolent system)
  • Conditioning & control of coolant and air flow (vehicle in the loop)
  • Control strategy development & validation
  • Component & system characterization
  • System efficiency investigations
  • Functional & durability validation
Thermal Vehicle Testing
  • Validation of vehicle thermal & energy management
  • Validation of cabin HVAC & thermal comfort system
  • Performance & efficiency verification
  • Calibration of thermal system control logic
  • Chassis dyno, test track and on road testing
Rear view of grey vehicle taillights on with fog in background
Rear view of grey vehicle taillights on with fog in background

Proving Ground

On-Site Proving Ground for Autonomous Driving, Functional & Endurance Testing

The proving ground in St. Valentin / Austria with its area of 40 ha has an optimal design for the testing of commercial vehicles and passenger cars. It provides a paved road with 850 m, rough roads and up to 7 km unpaved dirt road tracks with varying ascending slopes.

Our deep understanding about the definition of test collectives that reflect the required vehicle durability in real life in connection with the immediate availability of the proving ground, are the key advantages for customers during the development.

Heavy terrain, slopes with gradients up to 60%, a fording basin with a depth up to 1.8 m and special obstacles qualify this test track also for testing of off-road-, construction- or military vehicles. In addition free field- and ISO-noise measurements as well as test stands for cooling measurements are available.

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Vehicle Verification & Testing

  • Thermal Management
  • Energy Management
  • ADAS Function Testing
  • Acoustics and Vibrations
  • Drivability
  • Charging
  • Hybrid & ICE
  • On-Site Proving Ground / On-Road Testing
  • 4WD Chassis Dyno

ADAS Testing & Benchmarking

Following Tests are possible:

  • Adaptive Cruise Control
  • Autonomous Emergency Braking
  • Blindspot Detection
  • Lane Departure Warning
  • Birdview
  • Rear Automatic Braking
  • Lane Keep Assistant
  • Automatic Parking System
  • Lane Change Assistant
  • Adaptive Front Lighting
  • Vehicle Platooning
  • Rain Sensor
  • Intelligent Speed Assist (road sign recognition)

Homologation Support

  • Brake Homologation ECE R13
  • Steering Homologation ECE R79
  • Acoustic Homologation ECE R51
  • Advanced Emergency Brake Homologation ECE R131 / ECE R152
  • Lane Departure Warning ECE R130
  • Blind Spot Detection Homologation ECE R151
  • Adaptive Cruise Control ISO 15622 / SAE J2399
  • Installation of lighting and light-signalling devices ECE R48
  • SORT Measurements

Contact

Engineering Center Steyr GmbH & Co KG
Steyrer Straße 32
4300 St. Valentin
Austria

Office: +43 7435 501 0
Email: info.valentin.mpt@magna.com