Endurance and functional testing of combustion, hybrid and electric drivetrains on 48 test benches in Sandersdorf-Brehna.
FEV Dauerlaufprüfzentrum GmbH
Sandersdorf-Brehna (Brehna district) · Sandersdorf-BrehnaNew on Amplifa
About FEV Dauerlaufprüfzentrum GmbH
FEV Dauerlaufprüfzentrum GmbH (FEV DLP) was founded in 2007 in Sandersdorf-Brehna and is part of the internationally active FEV Group. The company operates an endurance and functional test center for vehicle powertrains of all types – from combustion engines and hybrid drivetrains through to purely battery-electric drives. At the Brehna site, there are today 48 engine and powertrain test benches on a site of around 60,000 m² with 9,000 m² of building space, including seven specialized e-mobility test benches with power outputs of up to 1.5 MW. The portfolio of services covers endurance and functional tests, engine power type testing (homologation in accordance with ECE-R 85), cold, low-temperature and thermal shock testing, as well as mechanical safety engineering with teardown inspection and documentation. 24/7 operation including engineering services and global project management shorten development and test times for customers from the automotive and supply industries. For high-voltage battery testing, the sister company FEV eDLP GmbH is operated at the same site.
- Site
- Sandersdorf-Brehna
- Processes
- Endurance and functional testing of vehicle powertrains (combustion engine, hybrid, electric), Engine power type testing (homologation, ECE-R 85), Low-temperature testing (continuous operation down to −12 °C), Thermal shock testing, Start-stop testing, Cold testing with defined heating and cooling gradients, E-mobility drivetrain endurance testing (up to 1.5 MW, passenger cars and heavy-duty), High-voltage battery and battery module development and validation tests
- Materials
- Combustion drivetrains, Hybrid drivetrains, Electric drivetrains, High-voltage batteries and battery modules
- Certificates
- UNECE Regulation 85 (ECE-R 85) certification of all engine test benches, UNECE R85 (ECE-R 85), audited by DEKRA, ISO 9001
- Founded
- 2007
- Employees
- 51–200
- Industries
- Automotive and supply industry, Passenger car drivetrains, Commercial vehicles/heavy-duty applications, E-mobility / battery technology
- 01
Project management and test planning (worldwide support, transport/shipping)
- 02
- 03
Endurance and functional testing in 24/7 operation
- 04
Automated failure monitoring (over 200 channels) and measurement technology
- 05
- 06
Final report and remote data evaluation around the clock
Test Methods and Test Benches
Combustion drivetrains
Endurance and functional testing as well as homologation type testing in accordance with ECE-R 85 for passenger car engines.
Hybrid drivetrains
Testing of modern hybrid powertrains with battery simulation and high-voltage technology from 48 V to 400–600 V.
Electric drivetrains
Endurance testing of e-drivetrains on specialized test benches up to 1.5 MW for passenger cars and heavy-duty applications.
High-voltage batteries and battery modules
Development and validation tests in the battery and high-voltage test center of FEV eDLP GmbH.
Locations
Sandersdorf-Brehna (Brehna district)
DEEndurance and functional test center (headquarters)
- Materials
- Combustion, hybrid and electric drivetrains
- 48 engine and powertrain test benches (including 32 engine test benches up to 600 kW)
- 4 powertrain test benches
- 5 dummy test benches
- 7 e-mobility drivetrain test benches up to 1.5 MW
- 5 low-temperature chambers (continuous operation down to −12 °C)
- Thermal shock systems
- Start-stop test benches
- Cold test benches
- Asynchronous machines 180–600 kW with energy recovery
- High-voltage technology from 48 V to 400–600 V, battery simulation on all test benches
- Automated failure monitoring with over 200 channels including vibration monitoring
Sandersdorf-Brehna
DEFEV eDLP GmbH – Battery and High-Voltage Test Center
- Materials
- High-voltage batteries, battery modules
- High-voltage battery test center for battery modules and high-voltage batteries
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Endurance and functional testing of vehicle powertrains (combustion engine, hybrid, electric)Testing | – | – | – | – | Combustion engines, Hybrid drivetrains, Electric drivetrains |
| Engine power type testing (homologation, ECE-R 85)Testing | – | – | – | – | – |
| Low-temperature testing (continuous operation down to −12 °C)Testing | – | – | – | – | – |
| Thermal shock testingTesting | – | – | – | – | – |
| Start-stop testingTesting | – | – | – | – | – |
| Cold testing with defined heating and cooling gradientsTesting | – | – | – | – | – |
| E-mobility drivetrain endurance testing (up to 1.5 MW, passenger cars and heavy-duty)Testing | – | – | – | – | Electric drivetrains |
| High-voltage battery and battery module development and validation testsTesting | – | – | – | – | High-voltage batteries, Battery modules |
| Testing | – | – | – | – | – |
| Duravelopment™ – integrated development and endurance testing (Road-to-Rig)Engineering | – | – | – | – | – |
| Global project management, commissioning and test support, transport logisticsEngineering | – | – | – | – | – |
11 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Engine test benches (up to 600 kW) | – | 32 | up to 600 kW | – | Sandersdorf-Brehna (Brehna) |
| Powertrain test benches | – | 4 | – | – | Sandersdorf-Brehna (Brehna) |
| Dummy test benches | – | 5 | – | – | Sandersdorf-Brehna (Brehna) |
| Low-temperature chambers (down to −12 °C) | – | 5 | – | – | Sandersdorf-Brehna (Brehna) |
| Thermal shock systems | – | – | – | – | Sandersdorf-Brehna (Brehna) |
| Start-stop test benches | – | – | – | – | Sandersdorf-Brehna (Brehna) |
| Cold test benches | – | – | – | – | Sandersdorf-Brehna (Brehna) |
| E-mobility drivetrain test benches (high-performance test benches up to 1.5 MW) | – | 7 | up to 1.5 MW | 2019/2024 | Sandersdorf-Brehna (Brehna) |
| Asynchronous machines for drivetrain simulation | – | – | 180 to 600 kW, energy recovery | – | Sandersdorf-Brehna (Brehna) |
| Engine and powertrain test benches (total) | – | 48 | – | – | Sandersdorf-Brehna (Brehna) |
| High-voltage battery test center (battery modules and high-voltage batteries) | FEV eDLP GmbH | – | – | 2019 | Sandersdorf-Brehna |
Additional services
Quality and Certification
All engine test benches are certified in accordance with UNECE Regulation 85 (ECE-R 85) and were audited by DEKRA Automobil GmbH; on this basis, type tests and homologations for engine-vehicle combinations are performed worldwide. The automated failure monitoring with over 200 channels including vibration monitoring protects the test item during 24/7 operation.
| Evidence | Sandersdorf-Brehna (Brehna district) |
|---|---|
| UNECE R85 (ECE-R 85), audited by DEKRA | |
| ISO 9001 |
Company History
- 2007
Founding of FEV Dauerlaufprüfzentrum GmbH (commercial register entry 14.02.2007, HRB 6148, Amtsgericht Stendal district court; groundbreaking in June 2007) in Sandersdorf-Brehna.
- 2008
Commissioning of 31 engine and powertrain test benches by the end of 2008.
- 2011
1st expansion stage: four additional engine test benches; retrofitting of all test benches with high-voltage technology and battery simulation.
- 2015
2nd/3rd expansion stage: six additional engine test benches (from 26 to 32); introduction of high-voltage technology in the 400–600 V range.
- 2019
Commissioning of seven specialized e-drivetrain test benches; establishment of FEV eDLP GmbH for battery and high-voltage testing.
- 2024
Expansion of e-mobility testing capacity with high-performance test benches up to 1.5 MW; the site now comprises 48 test benches.