The collaborative program set out to anticipate the safety behaviors of solid-state battery cells under increasingly demanding operational and regulatory conditions, and address technology-specific requirements, including pressure management and mechanical integrity at the cell and system levels.

The initiative combined Blue Solutions’ battery cell technology and AVL’s expertise in battery simulation, validation and safety assessment. Conducted on a non-exclusive basis, the collaboration allowed both partners to strengthen their programs while continuing to support broader industry progress.

Anticipating safety at scale

As battery technologies evolve toward higher performance and higher volumetric energy density, the joint program confirmed that safety can be embedded early in the design process.

The work focused on predictive safety simulations during cell technology scale-up, and evaluated technology-specific behaviors, including internal pressure management. Advanced abuse and failure scenario modeling, and alignment with emerging safety regulations, were also studied.

Toward thermal-propagation-free battery systems

The program also addressed thermal propagation (TP). By combining advanced modeling, pressure-aware design and safety-first architecture, the partners demonstrated pathways toward eliminating thermal propagation risks.

Simulation-based and validation test results demonstrated positive and consistent outcomes, including compliance even under the latest New Energy Vehicle regulations. The technology meets the GB 38031-2025 requirements.

The program confirmed that the intrinsically high volumetric energy density of Blue Solutions’ technology is safeguarded, while maintaining robust safety margins. Results demonstrated targets of up to 25% higher volumetric energy density compared with equivalent NMC Li-ion battery packs, alongside an expected 13% increase in gravimetric energy density.

Results and key lessons learned will be disseminated at leading international conferences and battery industry events.

“We are very happy to have collaborated with AVL,” said Olivier Caumont, battery systems director at Blue Solutions. “Their vision and mastery in multiple sectors, combined with our extensive manufacturing experience in solid-state battery manufacturing and pack integration, including the safety, thermal or mechanical aspects, have enabled us to confirm that our solution is fully aligned with market needs, and capable of fulfilling the most stringent safety requirements.”

“Working with Blue Solutions’ latest solid-state battery technology is a significant step forward for AVL,” added Paul Schiffbänker, director of battery development at AVL List. “It not only deepens our understanding of the specific safety characteristics of this next-generation chemistry but also actively drives the further development of our safety methodologies and battery design solutions. From advanced simulation-based prediction models to new validation and assessment approaches, this collaboration enables us to systematically embed safety into the development of future high-energy battery systems from the very beginning.”

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The test forms part of ongoing research into how multiple battery cells operate together within a complete pack, with a focus on energy density, thermal behavior and fast-charging capability in real-world conditions.

According to Donut Lab, the Verge TS Pro equipped with its battery technology charged in less than 10 minutes, making it “the world’s fastest charging electric motorcycle”, the company said.

“This is the first test we have published to a wider audience that demonstrates the performance and behavior of multiple battery cells in a real vehicle environment,” said Ville Piippo, CTO at Donut Lab. “The high energy density of our battery technology enables flexible battery pack design and superior performance even in more challenging applications, such as motorcycles, where space is limited and system simplicity is key. We are able to offer vehicle manufacturers packs with different energy capacities in the same physical size, with even the smallest packs having very high capacities.”

In the test, an 18kWh battery pack was charged using a public fast charger starting at approximately 20°C. The system reached a peak charging power of over 100 kW (around a 5C rate) for five minutes, with state-of-charge increasing from 10% to 50% in about five minutes. Overall, the motorcycle achieved a 10–70% charge in just over nine minutes, and 10–80% in approximately 12 minutes.

The solid-state-related battery architecture enables flexible pack design, enabling different energy capacities to be packaged within the same physical footprint, which is particularly relevant for space-constrained applications such as motorcycles.

“Our goal is to provide Verge users with the best possible user experience,” said Tuomo Lehtimäki, CEO of Verge Motorcycles. “The advantages of Donut Lab’s battery technology, such as ultra-fast charging, complement our goal seamlessly. The world’s fastest charging electric motorcycle, the Verge TS Pro, is also air-cooled. The battery pack used in this test is our standard model, but an extended range version is also available, with approximately two-thirds more energy capacity.”

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The lab’s high-current capability is designed to test large automotive cells and other high-power, high-capacity battery technologies, including those used in eVTOLs, data centers and stationary battery energy storage systems (BESS). Its extensive channel count is useful to companies with high-volume testing requirements, enabling hundreds of cells to be tested simultaneously under varying conditions. High-precision cyclers and advanced EIS tests also enable accurate long-term analysis and performance characterization, including cell ageing and end-of-life simulation, with modeling and calibration expertise provided by CamMotive’s specialist engineers.

The facility offers additional technical capability and services, including dynamic climatic chambers to replicate varying temperature conditions, and process thermostats for real-world thermal management testing. For high-power module and pack testing, the lab provides capability up to 1MW.

The primary purpose of the new laboratory is to support automotive OEMs and accelerate development timelines by gathering data for modeling, compliance and improved understanding, leading to enhanced performance, longer useful life and faster charging strategies.

In addition to the main facility, the laboratory also houses several lower current cyclers for testing of smaller capacity cells. In this way, the company aims to support innovation in battery technology, including startups working on the latest chemistries and organizations exploring battery options for new applications.

Bruce Campbell, director at CamMotive, said, “The launch of our new test facility marks the latest phase of CamMotive’s commitment to advancing battery technology and its applications. We provide solutions across the entire battery ecosystem, from early concept to end-of-line validation.

“Working with UK cell developers and digital modelers, manufacturers and integrators, we combine world-class testing infrastructure with decades of powertrain expertise to help our partners deliver sustainable solutions for road, air, sea transportation and stationary applications.”

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The tests evaluated the Donut Battery’s charging speed and thermal behavior during charging. They simulated a worst-case scenario in which the battery cell lacks active temperature controls and its temperature can rise freely at extremely high charging rates.

The measurement was done using two passive cooling configurations. In the first, the cell was surrounded by two lightly compressed aluminum cooling plates; in the second, the cell was attached to only one bottom cooling plate. Recharging rates are indicated using C-rates, where 1C means the battery is charged from empty to full in one hour (5C = ~12 min, 11C = ~5-6 min). Traditional lithium-ion batteries typically charge at 1C to 3C with active cooling, whereas in this measurement the charging power rises to significantly higher rates without active cooling. The testing began with a standard discharge capacity test at 1C, which was followed by rapid charging tests (at 5C and 11C) with both cooling configurations.

The results are in line with the five-minute charging time previously announced by the company.

The measurements indicate that the Donut Battery can tolerate high charging rates without active temperature control. Under the specified test conditions, the cell was charged at 5C for more than nine minutes, reaching 80% state of charge in approximately 9.5 minutes and 100% in just over 12 minutes. Following discharge, the cell delivered 100% of the charged capacity.

The battery cell was then recharged rapidly at the extreme speed of 11C. Charging from 0-80% was achieved in 4.5 minutes and a full 100% state of charge in just over seven minutes. When discharged after a full charge, 98.4-99.6% of the battery capacity was available for use.

Even though the testing conditions did not directly simulate cell behavior in a battery pack, the testing demonstrates the benefits of the Donut Battery as part of a pack. The battery cell does not require any particular compressive force and works well with passive cooling, which simplifies the battery pack architecture.

“Unlike other solid-state batteries requiring high compressive pressures and undergoing volume changes of up to 15-20% during recharging cycles, the Donut Battery does not require special compression or more extensive cooling. This greatly simplifies the structure of battery packs and enables solutions that are cost-efficient, powerful and better than traditional lithium-ion batteries in terms of energy and power density,” said Donut Lab CTO Ville Piippo.

In related news, Integrals Power LMFP cells pass 1,500-cycle test milestone with strong durability and low-temperature performance

The ongoing test program has achieved more than 1,500 charge and discharge cycles at a 1C rate, with the pouch cell retaining nearly 80% of its original capacity. The 1,000-cycle milestone was passed last year, at which point the retained capacity was more than 80%. Durability is critical for lithium-ion battery packs in applications requiring long service life with minimal degradation, such as electric vehicles.

Sub-zero testing by Cranfield University evaluated the pouch cell’s ability to retain high capacity in extremely low temperatures. The tested cell, from the same batch as those evaluated by QinetiQ, retained 85% of capacity at -25ºC and 68% at -30ºC. In comparison, benchmark LFP and LMFP chemistries typically retain around 50% and 40%, respectively.

In addition to durability and performance, Integrals Power’s LMFP material offers lower cost, improved safety, reduced toxicity, less reliance on critical minerals and a smaller carbon footprint compared with nickel manganese cobalt (NMC) chemistries commonly used in EV batteries. It also provides higher energy density than LFP.

Integrals Power founder and CEO Behnam Hormozi said, “Independent, third-party testing by industry experts is a cornerstone of our business, and these latest results from QinetiQ and the University of Cranfield are invaluable in providing trusted and credible data to our customers around the world.

“The results prove that batteries made from our LMFP material can last longer, and perform better in sub-zero conditions. Overcoming the compromises and limitations imposed by existing cell chemistries is essential if battery power is to realize its full potential across a range of sectors, and we’re showing that it can do exactly that.”

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As electrification continues to transform the automotive sector, developers are under increasing pressure to validate systems that must operate reliably across a broad spectrum of conditions. The rapid expansion of electric mobility is driven by technological advances, global CO₂ reduction goals and supportive regulatory frameworks. Charging infrastructures are scaling, vehicle architectures are evolving, and OEMs are compressing development timelines. With this acceleration come engineering challenges that differ fundamentally from those of combustion engine platforms, ranging from high-voltage safety to the integration of complex power electronics.

At the center of these challenges lies thermal management. Batteries, power electronics and electric motors are highly sensitive to temperature fluctuations. Their efficiency, durability and safety depend on precisely regulated heat flows. Cabin climate control also becomes a strategic efficiency factor because electric vehicles do not generate waste heat from an internal combustion engine. Alternative heating concepts must therefore maintain comfort while preserving driving range. As a result, testing technology for thermal management components has become a pivotal enabler for innovation across the EV sector.

Poppe + Potthoff Maschinenbau, a Germany-based company, develops modular test benches designed to reproduce thermal and hydraulic conditions encountered in electric vehicle applications. The systems are built to support comprehensive testing methodologies that address efficiency, reliability and safety requirements. Integrated measurement and control technologies allow detailed analysis during development and validation processes.

The growing demand for robust thermal management testing

The shift toward electric vehicles has elevated thermal management to a defining performance factor. Batteries must remain within a narrow thermal window to ensure longevity and safety. Inverters and power electronics require cooling to maintain efficiency. High-performance traction motors generate significant heat during dynamic loads. At the same time, growing variability increases the overall validation workload. Each cooling circuit comes with its own media requirements and operating patterns that must be reproduced with high fidelity. Test systems therefore need not only faster reconfiguration but also precise calibration to the functional profile of each module. This reinforces the importance of modular test architectures capable of covering multiple cooling variants within a single infrastructure, thereby shortening development timelines and improving overall test efficiency.

Testing these systems under controlled conditions is crucial to validate long-term functionality. Components such as hose assemblies, valves, cooling plates, heat exchangers, electric pumps, pressure vessels and entire cooling loops must tolerate thousands of load cycles, temperature shifts and flow variations over the typical 10- to 15-year service life of an electric vehicle.

Poppe + Potthoff Maschinenbau’s portfolio addresses this need with dedicated solutions for dynamic pressure cycling, static pressure holding, flow measurement, burst pressure testing and functional testing of live components. These test benches replicate the thermal, mechanical and electrical stresses that occur during daily operation, enabling engineers to detect weak points early and optimize materials, joining processes and overall system architecture.

Dynamic pressure cycling: simulating lifetime stress in accelerated time

A central application is the simulation of pressure fluctuations in cooling and heating circuits. Components are placed inside the test chamber and exposed to load profiles that mirror real driving conditions. Depending on the system, the test medium is circulated at temperatures between -40°C and +140°C. Water-glycol mixtures such as Glysantin G40, G44 or G48 are commonly used.

Cooling circuits are tested between -40°C and +20°C, while heating circuits undergo thermal cycling from +20°C up to +140°C. Many components must withstand more than 100,000 load changes during their lifetime, and these conditions can be reproduced in the laboratory within only a few weeks. The system’s programmable pressure waveforms, either sinusoidal or trapezoidal, run at frequencies between 0.2Hz and 2Hz or higher. Flow rates range from 1 to 50 liters per minute at pressures between 0.2 and 12 bar or more. This level of control makes it possible to test plastics, metals, composites and sealing materials under consistent and reproducible conditions.

Test standards evolve continuously. Poppe + Potthoff test benches can be configured to meet specifications such as MBN 10306, VW 8000, GS 95024 3 1 and GMW 14193. Climate chamber integration enables combined environmental and functional stress testing, including tests with overpressure and underpressure, if required.

Identifying weak points and optimizing system design

Material transitions such as weld seams, press fits and adhesive bonds often represent sources of fatigue. By exposing components to realistic pressure and temperature cycles, engineers can identify early-stage cracking, swelling, deformation and leakage. These insights help refine design choices, improve production quality and stabilize system performance long before large-scale manufacturing begins. Throughout the test, inlet and outlet temperatures, flow rates, pressure drops, current and voltage for active components and ambient conditions are measured continuously. Thermal sensors placed on the test object highlight areas of energy loss or potential overheating, contributing valuable information for further optimization.

Accelerated durability testing for long-term reliability

Long-term tests generally run for 20 to 30 days, depending on the chosen load frequency. Ambient and media temperatures vary according to the test specification, and all key parameters are logged continuously. This accelerated method simulates several years of operation within a matter of weeks. It reveals aging behavior, degradation patterns and the effects of repeated thermal and mechanical stress on component performance. The data supports predictive maintenance approaches, extended warranty assessments and material qualification.

Functional testing under realistic electrical loads

Efficiency is a decisive performance factor in electric vehicles, since every watt drawn by thermal management components affects vehicle range. Poppe + Potthoff Maschinenbau therefore offers functional test benches that evaluate performance and energy consumption under low- and high-voltage conditions.

Cooling and heating units, control valves and pumps can be operated at voltages between 0 and 24V DC or up to 1,500V DC and 150A to simulate onboard battery or traction battery operation. Tests are carried out across a thermal spectrum from -40°C to +100°C, with optional climate chamber integration extending the ambient range to +140°C. Comparing measurements before and after a durability test shows how components degrade over time. These insights are essential for planning service intervals, improving efficiency and safeguarding long-term system stability.

Safety, usability and digital integration

Safety is an integral part of every system. Test chambers are built from welded stainless steel and equipped with high-strength laminated safety glass. A closed medium circuit prevents the formation of hazardous vapors. Operation is streamlined through recipe management, which enables predefined test sequences to be selected via PC or handheld scanner. National Instruments’ LabView platform provides comprehensive data visualization and acquisition. All test data is stored automatically and can be exported for further analysis. The open software architecture makes it possible to integrate additional sensors and custom data channels whenever needed.

Enabling the next generation of electric mobility

As electrification advances, precise and adaptable testing solutions are essential for validating new concepts and ensuring safe, efficient and durable electric vehicles. By reproducing the interaction of temperature, pressure, flow and electrical load, the test setups provide engineers with data that can support the design and assessment of components across the full service life of an electric vehicle. This contributes to a more detailed understanding of thermal management behavior within modern electric mobility.

Rapid electrification is increasing demand for advanced charging infrastructure, from fast charging for passenger vehicles to megawatt-level solutions for heavy-duty and industrial fleets. Engineers and manufacturers face growing complexity due to interoperability challenges, strict safety requirements and evolving global standards such as MCS, CCS, ISO 15118, GB/T, and CHAdeMO. Without scalable, comprehensive testing, manufacturers risk delays, costly redesigns and inconsistent real-world performance.

Keysight‘s solution combines high-power hardware, software-defined scalability and standards compliance. The solutions enable flexibility and scalability, so that customers can accelerate development and stay ahead of emerging testing requirements.

The SL2600A Megawatt Charging Discovery System enables validation of next-generation megawatt charging for heavy-duty applications, supporting voltages up to 1,500V and currents up to 1,500A. Its modular, upgradable architecture enables engineers to test both electric vehicles and charging stations within a single system, increasing flexibility and reducing total cost of ownership. The SL2600A was designed with future standards in mind, including NACS and CCS.

Complementing this, the enhanced SL1047A Scienlab Charging Discovery System – High‑Power Series delivers software‑scalable performance starting at 400A and 1,000V, with the ability to expand up to 800A and 1,500V without requiring hardware replacement. With support for all global charging standards, including full compliance with GB/T 2024, the system enables comprehensive conformance and interoperability testing for worldwide EV charging ecosystems. It also introduces enhanced charging communication test capabilities, featuring significant improvements and extended functionality to address increasingly complex EV charging requirements.

Luis Hurtado, PHD and chief technology officer at Milence, a Dutch company specializing in charging infrastructure for electric heavy-duty trucks, said, “To drive the transition to sustainable heavy-duty transport, we need charging solutions that are fast, scalable and future-ready. Our partnership with Keysight helps us ensure that our infrastructure meets the highest standards from day one.”

Thomas Goetzl, vice president and general manager for Keysight Automotive & Energy Solutions, added, “The transition to high-power and megawatt-level charging is a pivotal moment for the EV industry. Our latest test solutions give manufacturers and engineers the confidence to innovate quickly and deliver reliable charging systems that meet global standards. This launch reinforces Keysight’s commitment to enabling the future of e-mobility and supporting a sustainable transportation ecosystem.”

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The fully electric drivetrain provides long-range, high-charging performance with 800V technology and efficient energy recuperation, making the BMW M Neue Klasse a versatile everyday vehicle. Its newly developed architecture, featuring centrally controlled individual wheel drive, reportedly opens a new dimension in driving dynamics and enhances the safety of all next-generation BMW M vehicles.

The Neue Klasse’s advanced central control and electronics architecture also improves the driving dynamics. Four high-performance computers, called Superbrains, manage driving functions, automated driving, infotainment and comfort features. This setup enhances performance through faster data exchange and allows next-generation BMW M models to receive quicker updates and upgrades.

BMW M eDrive concept

The BMW M Neue Klasse has been developed from the ground up. At the core of the new architecture is BMW M eDrive, which is based on the BMW Gen6 technology of the Neue Klasse.

BMW says that M Dynamic Performance Control, using M-specific Heart of Joy software, enhances driving dynamics, safety, traction, recuperation and responsiveness.

The Neue Klasse features two electric drive units on the front and rear axles, each with one electric motor per wheel. Each of the four electric motors drives one wheel. This combines the advantages of rear-wheel and all-wheel drive while enhancing driving dynamics on the road and racetrack. Additionally, the front axle can be completely decoupled.

BMW M eDrive’s electric drive units are BMW M’s most powerful, with parallel motors powering each wheel via dedicated gearboxes. The drive units also integrate the inverter for controlling the electric motors and the oil supply. The system enables precise control of torque and power at each wheel, enabling optimal traction, continuous torque distribution between the braking system and electric motors, and brake energy recuperation right up to the limit.

High-voltage battery

The high-voltage battery, boasting over 100kWh of usable energy as the powerhouse for the BMW M eDrive system, has been adapted to meet the demands of high-performance vehicles.

With a focus on compatibility with both road and racetrack use, BMW’s Design to Power approach uses a performance-optimized Gen6 cylindrical cell with an enhanced cooling system and the Energy Master control unit, enabling higher power outputs for road and track use. With BMW M-specific solutions, the Gen6 high-voltage battery in the fully electric high-performance models delivers even greater peak and charging performance. Additionally, within the Gen6 technology, the Neue Klasse models offer the highest recuperation values. The high-voltage battery housing also serves as a structural component of the vehicle and is connected to the front and rear axles. The resulting higher stiffness leads to improved driving dynamics.

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A H₂ICE uses zero carbon hydrogen fuel in tried-and-tested engine technology, presenting a viable path for decarbonizing medium and heavy-duty transportation, such as trucks and buses.

Announced back in July, the new testing area forms part of JM’s existing site in Gothenburg, Sweden, and has been completed on time and on budget, representing a £2.5m (US$1.67m) investment over three years.

The investment has further expanded JM’s H₂ICE testing capability, enabling it to test full engines for the first time.

Tauseef Salma, JM chief technology officer for clean air, commented, “This investment shows JM is backing H₂ICE as a ready-to-go technology that will enable mobility partners to meet their decarbonization and climate goals. Our state-of-the-art Gothenburg facility positions JM as a world leader in sustainable technology solutions, transforming energy and reducing carbon emissions.”

The Gothenburg installation supports H₂ICE engines up to 600kW (800hp). It will test the performance of catalysts within the wider engine aftertreatment and control systems, providing key insights into the development of hydrogen mobility solutions. Gothenburg is already home to medium and heavy-duty diesel engine test cells.

The H₂ICE investment follows JM’s collaboration with Cummins, and technology partners Phinia and Zircotec, who launched Project Brunel in November 2021. This partnership was successfully concluded in March 2025, delivering proof points towars significant improvements in H₂ICE engine performance and durability.

The new Gothenburg H₂ICE facility includes an on-site hydrogen supply and storage area with a compressor and intermediate storage tank, hydrogen supply and storage up to 413 bar, a hydrogen flow meter and analyzer with exhaust measuring instruments and all appropriate control, sensing and safety systems.

Salma added, “For more than two centuries, JM has helped tackle some of the world’s biggest challenges. We continue to do so today because it’s in our DNA. The opening of this new testing facility shows our commitment to strategic partnerships to drive innovation, strengthening the potential of H₂ICE as a net zero pathway for commercial vehicles.”

In related news, Kistler adds real-time electric and hybrid drivetrain analysis to KiBox2

This new capability delivers real-time measurement, visualization and recording of all key drive parameters, with advanced cycle detection and ultra-fast calculation windows suited for highly dynamic, precision testing.

The modular and scalable KiBox2 E-Powertrain Analysis can be configured for a wide variety of measurement scenarios and areas of application – on land, in the water, or in the air.

KiBox2 E-Powertrain Analysis is a key tool for R&D in electric and hybrid drive systems. Designed to support every development stage – from integration and calibration to optimization and verification – it enables measurements on individual components such as power electronics, inverters, e-motors and resolvers, as well as on complete assemblies. As a full solution, it handles the demands of DC and AC testing, high- and low-voltage measurements and energy management system analysis.

With up to 64 measurement channels and powerful processing functions, the scalable system captures all key signals across the entire powertrain. Unlike standard DAQ systems, KiBox2 E-Powertrain Analysis processes data immediately through dedicated software, enabling real-time visualization and analysis of application-specific e-machine parameters. It can also measure and process currents from high-voltage current transducers as well as signals from standard current clamps.

Testing electric and hybrid drives

For data acquisition and power analysis of electric powertrains, KiBox2 E-Powertrain Analysis comprises three compact components: The KiBox2 16-channel measuring unit works as a compact, mobile power analyzer for real-time measurement, calculation and visualization with rapid processing of 2.5MS/s per channel.

The HVAQ four-channel high-voltage module is electrically isolated and supports measurement ranges up to ±1,000Vrms/±1,500 Vpeak, meeting 1,000V CAT II/600V CAT III safety standards. The HCAQ four-channel high-current module, together with the Current Conditioner Box, enables measurement ranges up to 2,000A and supports external zero-flux current transducers.

The system integrates easily into test stand automation and, with its compact and robust design, is also suitable for in-vehicle testing. For on-track use, KiBox2 E-Powertrain Analysis withstands strong vibrations and can be powered directly from the vehicle. Its high-performance electrical power analyzer enables precise measurement and calculation of power flows and losses, supported by high-resolution data storage for detailed offline analysis

KiBox2’s user interface enables it to be set up quickly. The advanced signal conditioning simplifies the analysis of electric power, making it possible to quickly identify losses. The intelligent algorithm ensures precise real-time cycle detection and can be flexibly configured up to one-quarter of an electrical cycle. All data is saved in an ASAM-compatible format. For custom workflow integration, a corresponding converter can be used to output alternative data formats.

Power analysis can be carried out simultaneously on electric powertrains and powertrains that use combustion technologies, such as range extenders, with a single system. Synchronized data acquisition and calculation of crank-angle and time-based measurands allow for combined energy flow analysis in both domains. Moreover, mechanical torque systems can be directly connected to KiBox2 via analog or digital inputs. By including physical parameters like speed and torque, KiBox2 is expanding the range of applications to include mechanical power analysis.

Vehicle efficiency has long been a key focus in the automotive industry, even before the rise of alternative drive technologies. By combining measurements and analysis of both electric and combustion drives, and by capturing mechanical signals from torque systems, Kistler offers R&D teams a highly versatile testing platform. To support data processing, Kistler has expanded its Cockpit software with the latest E-Powertrain application module, while jBEAM Powertrain provides powerful tools for further data analysis.

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