Like all other vehicle components and modules, the electric drive and battery are developed individually. They are then integrated into the vehicle, where the networking of the system controls is also a challenge. Further development and functional testing of the overall system can take place on the road at the proving ground, but this is limited by restrictions in terms of test parameters and repeatability. The integration of the powertrain into the vehicle is realized at FKFS using the Road-to-Rig concept. This method simulates a vehicle’s real-world environment on the test bench, allowing functions, modules and components to be tested in interaction.

Highly dynamic wheeled machines allow any route to be simulated, from city driving to mountain passes. The vehicle sensors are provided with the appropriate environmental conditions for the route (e.g. GPS data). Vehicle operation is fully automated. This means that there is no danger to people, even during extreme maneuvers, and exact repeatability is guaranteed.  The FKFS Road-to-Rig test bench offers further opportunities to investigate borderline areas, such as how the powertrain and battery behave in cold (down to -30°C) or hot (up to +50°C) conditions and whether the vehicle application can cope with these situations.