Test Bench Solutions

Testing services and test bench engineering

ENGtron supports test execution for components and complete systems, as well as the planning, setup and automation of test benches.

in-house test benches
60 km/h
roller test bench for Pedelec & S-Pedelec
R200
range test under identical conditions
DAkkS
calibrated torque sensing

What we do

Services

Clear and technically grounded execution with a focus on reproducible results and robust implementation.

Testing services

We do not test for the report. We test so your drivetrain works in the end.

ENGtron takes over testing tasks when it matters: with in-house test benches, automotive measurement background and years of e-bike drivetrain experience from series development.

Test bench engineering

We do not just build test benches. We build your tool.

ENGtron develops and builds custom test benches for Pedelec and S-Pedelec drive systems. We combine automotive-grade measurement precision with practical day-to-day bench experience.

Software and automation

Hardware measures. Software determines what comes from it.

A test bench is only as good as its control and data acquisition. ENGtron develops and integrates the software side of test bench systems - from real-time control to controller development and data analysis.

Testing services

Sometimes internal capacity is not enough. Sometimes a second independent instance is needed for validation. And sometimes you need someone who not only measures but understands what the data means.

Our goal is to bring your product to series readiness together with you or to improve it in a focused way. We do not deliver data overload, but solid decision foundations that matter.

We identify issues before they become expensive because we know our test benches, understand systems quickly and know what drivetrain development looks like in practice.

Typical use cases:

  • Capacity bottlenecks in internal testing
  • A second independent instance for result validation
  • Reproduction and analysis of anomalies - we reproduce field findings or unclear test results and make them measurable and explainable
  • Development-accompanying validation across multiple iterations

ENGtron - testing with automotive and e-bike development DNA.

Test bench engineering

A good test bench is not an off-the-shelf product. It is built from understanding what must be measured - and why.

That means no overengineered system with features you do not need, and no compromises where precision decides. We think from the measurement target, not from a component catalog.

Our in-house benches are developed end to end by ourselves: measurement technology, power electronics - from circuit design through the selection and dimensioning of the hardware components - and the software. Exactly this depth is what we bring into your project.

What ENGtron brings:

  • Hands-on experience operating test benches with precision torque sensing and EtherCAT-based measurement
  • System understanding across mechanics, drive control and data acquisition
  • Realistic assessment of effort, precision and limits - without a sales perspective
  • Interface between test bench technology and drivetrain development: we know which data truly matters in development

Typical projects:

  • New build of a drivetrain-specific functional test bench
  • Expansion or modernization of existing test infrastructure
  • Setup of endurance or load-change test benches
  • Integration of measurement technology into existing test environments

ENGtron - test bench engineering with an operator's perspective.

Software and automation

As a turnkey system or as engineering services directly on your site.

We do not build black boxes. You get a system you understand and can further develop yourself.

The real-time control and the automation software are our own in-house developments - not licensed black boxes. We can offer this know-how, and support migrating away from cost-intensive licensing models, as a standalone service.

Controller development for test benches:

A test bench provides exactly the conditions a test requires - no more, no less. That requires precise and stable control. ENGtron develops and calibrates controllers for all relevant operating modes:

  • Speed control - stable target speed under changing load conditions
  • Torque control - precise torque setpoint for reproducible test conditions
  • Power control - load-point-accurate power tracking
  • Position control - for angle-accurate or path-dependent test scenarios
  • Transition management - clean switching between control modes during operation

In-house test bench software: We support migration from cost-intensive licensing models to proprietary software tailored to your requirements and flexibly adaptable at any time.

Testing focus

E-Bike test services for Pedelec and S-Pedelec systems

ENGtron takes over development-accompanying validation for Pedelec and S-Pedelec drive systems - from motor characterization to series readiness. No setup effort, no onboarding delay. Directly with the engineer.

In-house roller test bench
In-house roller test bench

Why teams bring in ENGtron

Development-accompanying testing on our roller test bench up to 60 km/h: simulate road loads, record the power curve, test thermal behaviour under sustained load, compare variants and de-risk decisions faster. Got a specific question? Talk to us about customer-specific tests, we reproduce your scenario reliably.

System benchmark: DJI, Bosch, Pinion, Mahle & more

We compared DJI, Bosch, Pinion, Mahle and further systems under identical R200 conditions. The benchmark reveals clear efficiency differences and helps prioritize development decisions faster.

Development motormost efficient
7.35 Wh/km
DJI Avinox M1
7.76 Wh/km
Bosch CX Gen5
8.26 Wh/km
Pinion E1.12
8.92 Wh/km
Bosch CX Gen4
9.26 Wh/km

Real R200 measurement (2025), identical conditions: 20 km/h, 70 W rider power. Specific consumption in Wh/km, development motor most efficient.

Measurement technology

Torque sensors
HBM T210, DAkkS-calibrated, 0.1%
Measuring range
±200 Nm (brake roller), ±100 Nm (rider side)
Speed
Up to 60 km/h, integrated speed capture
Electrical power
Traceable measuring equipment
Real-time system
Linux Real-Time, EtherCAT bus, 1 ms cycle time
Safety
Pilz PNOZmulti safety PLC, CE target documented
Control modes
Speed, torque, power and position control
Pedal torque profile
Application of a realistic sinusoidal torque curve per pedal revolution, per side
Electrical power accuracy
±2%
Energy / range accuracy
±1 to 2%
Mechanical power accuracy
load-dependent: approx. ±2% at R200

Our roller bench services:

  • R200 range test
  • Power curve with cadence dependency
  • Cut-off behavior at the upper Pedelec/S-Pedelec speed limit
  • Endurance tests
  • Maximum load test (temperature/derating behavior)
  • Customer-specific tests
  • Test automation
Request a project

Second in-house test bench

Drivetrain test bench for components and systems

A high-precision drivetrain test bench, expandable for system tests, for motors, gearboxes, complete drivetrains and robotic actuators, with automated control and monitoring of the connected components, real-time simulation and DAkkS-calibrated torque sensing.

In-house drivetrain test bench
In-house drivetrain test bench

High-precision drivetrain test bench with system-test capability

From torque calibration to endurance runs to full system tests: the bench drives, controls and monitors the complete drive system including battery, control units and further actuators, and tests it automatically. Reproducible test conditions, precise measurement technology and analysis by an engineer who knows his test bench.

Measurement technology

Torque sensors
2× HBM T210 (200 Nm), DAkkS-calibrated, 0.1% - same model as the e-bike bench
Measuring range
±200 Nm, reproducibility ±0.2 Nm
Angle measurement
High-resolution motor encoder, higher on demand
Real-time system
Linux Real-Time, EtherCAT bus, 1 ms cycle time
Safety
Pilz PNOZmulti safety PLC
Control modes
Speed, torque, power and position control
Pedal torque profile
Application of a realistic sinusoidal torque curve per pedal revolution
Electrical power accuracy
±2%
Energy / range accuracy
±1 to 2%
Mechanical power accuracy
load-dependent: approx. ±0.4 to 1% at mid load

Our drivetrain test bench services:

  • Torque sensor calibration (DAkkS-traceable)
  • R200 range test (also possible on this bench)
  • Endurance and load-change runs
  • System tests with active control and monitoring of the connected components
  • Efficiency measurements across operating points
  • Torque and angle sensor validation
  • Automated regression tests according to the V-model
  • Customer-specific tests
  • Validation and testing of robotic actuators (motors, gearboxes, drive units)
Request a project

Working together

From request to reliable data

Lean, transparent and without detours - this is how a project with ENGtron runs.

  1. 01

    Initial call

    You describe your task, we clarify the measurement goal and feasibility - directly with the engineer.

  2. 02

    Concept & quote

    You receive a clear scope with effort, precision and limits - realistically assessed, without a sales perspective.

  3. 03

    Execution & measurement

    Setup, testing and analysis on our benches or at your site - with regular updates on progress.

  4. 04

    Results & handover

    Reproducible data and clear recommendations - and for test bench projects, all the way to commissioning at your site.

Advantages

Why ENGtron

Pragmatic engineering, modern tooling and a track record of successful projects.

What sets ENGtron apart

Lean structure, deep technical expertise, and direct engineer-to-engineer collaboration. No overhead, no middlemen - just precise engineering and reliable results.

Let's talk about your measurement task

Describe your task in two or three sentences - you will get an honest assessment of feasibility, effort and timing. No sales pitch, no detours.

Your project stays confidential. On request we work under NDA, gladly even before the first technical conversation.

Contact person: Maximilian Boger-Liebzeit, M.Eng.

E-mail / Teams: max@engtron.de