Testing, test bench construction and test bench software for drive systems, e-bikes and special machinery
ENGtron – Maximilian Boger
Metzingen (company headquarters) · Reutlingen (test field)New on Amplifa
About ENGtron
ENGtron is an engineering service provider run by Maximilian Boger, M.Eng., based in Metzingen with a test field in Reutlingen. The company supports development departments in the planning, construction, automation and operation of test benches as well as in test execution on two in-house test benches: a roller dynamometer (eChecker, retrofit) for Pedelec and S-Pedelec up to 60 km/h including the R200 range test, and a drivetrain test bench with two DAkkS-calibrated HBM T210 torque sensors (0.1 %), Linux Real-Time, EtherCAT and 1 ms cycle time. The service areas include testing and validation, test bench construction including endurance and load-change test benches, retrofit and modernization of existing systems, as well as special machinery such as a click-and-swipe test bench for automated touchscreen tests built from a converted CNC gantry milling machine. The test bench software is an in-house development and is delivered license-free with source code. Focus areas are drive systems from automotive and e-bike; reference customers include system benchmarks for drives from DJI, Bosch and Pinion.
- Site
- Metzingen
- Processes
- Testing on in-house test benches (drive validation Pedelec/S-Pedelec), Roller dynamometer testing for Pedelec & S-Pedelec up to 60 km/h (driving resistances, R200 range,, Test bench construction (drive-specific functional test benches, endurance and load-change test, Test bench software & automation (real-time control, controller development, Torque and power measurement (HBM T210, DAkkS-calibrated, 0.1 %; voltage and current clamp, System benchmark of e-bike drives (DJI, Bosch, Pinion) under identical R200 conditions, Drivetrain test bench testing: shifting operations under load, torque drop-off analysis, endurance, Automated touchscreen/display testing (click-and-swipe, adjustable actuation force,
- Materials
- E-bike drives / Pedelec systems (DJI, Bosch, Pinion), Roller dynamometer (Retrofit), Torque sensor technology, Linux Real-Time control, Test bench software and test automation, Safety PLC
- Certificates
- DAkkS-calibrated measurement technology, ISO 9001
- Industries
- Automotive, E-Bike / Pedelec & S-Pedelec, Special machinery construction, Drive systems, Display/HMI manufacturers
- 01
Requirements analysis of the measurement task
- 02
Design and hardware engineering of the test bench
- 03
Assembly and commissioning
- 04
Integration of measurement technology and power electronics
- 05
Development of real-time control and user interface
- 06
Test execution, evaluation and validation
Services and Technology
Roller dynamometer (Retrofit)
Retrofit of the series production test bench with more powerful test bench motors, proprietary software and an independent safety concept for Pedelec and S-Pedelec testing up to 60 km/h.
Torque sensor technology
Two DAkkS-calibrated torque sensors (0.1 %) on the drive and output side for ±200 Nm and ±100 Nm respectively.
Linux Real-Time control
Proprietary real-time control with 1 ms cycle time for speed, torque, power and position control.
Test bench software and test automation
License-free user interface with source code, live visualization with 10 ms cycle time and automated test sequences via Python or CSV.
Safety PLC
Safety concept for automated endurance runs with a CE target image.
Locations
Metzingen
DECompany headquarters
Reutlingen
DETest field with in-house test benches (drivetrain test bench, eChecker roller dynamometer)
- Lot size
- Individual tests up to endurance runs
- Materials
- Pedelec and S-Pedelec drive systems
- Drivetrain test bench (in-house build, 2× HBM T210, EtherCAT, 1 ms)
- eChecker roller dynamometer (retrofit, up to 60 km/h)
- Pilz PNOZmu/PNOZmulti Safety PLC
Test Benches and Reference Projects
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Testing on in-house test benches (drive validation Pedelec/S-Pedelec)Testing | – | – | – | – | – |
| Roller dynamometer testing for Pedelec & S-Pedelec up to 60 km/h (driving resistances, R200 range,Testing | – | – | – | – | – |
| Test bench construction (drive-specific functional test benches, endurance and load-change testEngineering | – | – | – | – | – |
| Test bench software & automation (real-time control, controller developmentEngineering | – | – | – | – | – |
| Torque and power measurement (HBM T210, DAkkS-calibrated, 0.1 %; voltage and current clampTesting | 0.1 % | – | – | – | – |
| System benchmark of e-bike drives (DJI, Bosch, Pinion) under identical R200 conditionsTesting | – | – | – | – | – |
| Drivetrain test bench testing: shifting operations under load, torque drop-off analysis, enduranceTesting | – | – | – | – | – |
| Automated touchscreen/display testing (click-and-swipe, adjustable actuation force,Testing | – | – | – | – | – |
| Retrofit and modernization of existing test benches (motor upgrade, independent safety concept withEngineering | – | – | – | – | – |
5 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Roller dynamometer (Pedelec & S-Pedelec) | eChecker (Retrofit) eChecker | 1 | up to 60 km/h; torque ±200 Nm (brake roller), ±100 Nm (rider side) | – | Test field Reutlingen |
| Drivetrain test bench | In-house build | 1 | 2× HBM T210 torque sensor (200 Nm), Linux Real-Time, EtherCAT, 1 ms cycle time | – | Test field Reutlingen |
| Click-and-swipe test bench (converted CNC gantry milling machine) | – | 1 | 3 axes, stylus on Z-axis, adjustable actuation force | – | – |
| Torque sensor | HBM T210 | 2 | ±200 Nm (brake roller), ±100 Nm (rider side); 0.1 % DAkkS-calibrated | – | Reutlingen |
| Safety PLC | Pilz PNOZmu / PNOZmulti | – | – | – | Reutlingen |
Additional services
Reference customers
Measurement Technology and Quality
The measurement technology includes DAkkS-calibrated HBM T210 torque sensors with 0.1 % accuracy as well as traceable voltage and current clamps; test procedures are safeguarded by automated, reproducible test sequences with live visualization of all measured variables.
| Evidence | Reutlingen |
|---|---|
| DAkkS-calibrated measurement technology | |
| ISO 9001 |
Career and History
- 2009
B.Eng. degree in Mechanical Engineering (HTWG Konstanz), bachelor's thesis at Martinrea Honsel
- 2013
M.Eng. degree in Automotive Systems Engineering (HTWG Konstanz), master's thesis at Andreas Stihl AG & Co. KG
- 2015
Development engineer for chassis control systems at Testart GmbH (contractor: Porsche AG), Leonberg; project management of ride height control for Panamera, Cayenne, Taycan
- 2019
Development engineer for e-bike systems and test benches at BrakeForceOne GmbH (a subsidiary of ZF Friedrichshafen AG); ABS function development, test bench responsibility, two patent applications as inventor
- 2026
Founding of ENGtron (testing, test bench construction, software & automation); transfer of the drivetrain test bench and the eChecker roller dynamometer to the Reutlingen test field