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How UTAC and Unico Are Pioneering EV Test Bench Innovation for the Electrified Future
As electric vehicle (EV) development surges forward, the demand for sophisticated, flexible, and high-efficiency testing solutions has never been greater. At the heart of this technological transformation lies the evolving EV test bench. It plays a central role in validating e-motors, inverters, and powertrains. And as EV technology advances, this bench becomes even more essential. In a recent Munro team visit to UTAC’s Michigan facility, Don Wright from Unico and Dustin Harrison from UTAC walked through how their collaborative approach is redefining EV test bench innovation for OEMs and tier-1 suppliers.
From Engine Test Cells to E-Motor Labs
UTAC’s advanced facility in Northville, Michigan, stands as a symbol of automotive evolution. Engineers originally designed the test cells for internal combustion engine testing, but UTAC has now repurposed them to support ultra-high-speed e-motor and EDU (electric drive unit) testing. UTAC integrates specialized dynamometers and liquid-cooled silicon carbide drive systems from Unico. As a result, these reengineered benches are able to simulate real-world EV performance with precision.
Unico’s silicon carbide (SiC) drives pair with high-speed dynos such as the Dynamic E Flow system. Together, they create load profiles resulting in tests that closely mirror real in-vehicle scenarios. These setups allow engineers to analyze inverter calibration, assess motor efficiency, and replicate complex thermal conditions—such as extreme cold testing with -40°C glycol—essential for understanding EV behavior across all environments.
More Than Pass/Fail: Calibration, Efficiency, and Real-World Replication
EV testing is no longer a one-and-done verification process. UTAC’s engineers work closely with clients on developmental tests that iterate motor-inverter performance to optimize power and efficiency. As Harrison noted, software engineers often work side-by-side in the test bays to identify anomalies discovered in the field and fine-tune inverter algorithms in real time.
This tight motor-inverter integration matters. While it’s tempting to believe that any inverter will work with any e-motor, mismatched components can result in performance loss or inefficiencies. True optimization can take months of collaborative calibration—especially if OEMs want to reduce battery drain and extend vehicle range. By identifying the motor’s most efficient operating window and replicating varied drive conditions, UTAC helps ensure that the end product performs reliably under diverse load cases.
Flexibility Built into the Floor
A standout feature of UTAC’s EV testing solution is its adaptability. Each test cell is mounted atop a seismic mass—an isolated concrete foundation designed to mitigate vibration at high RPMs (up to 25,000). Heavy-duty steel fixtures and flexible bed plates allow rapid reconfiguration to accommodate different motors, inverters, or entire e-axle systems.
This modular approach extends to thermal systems, where embedded chillers, heaters, and coolant routing support a wide range of temperature simulations. UTAC even operates its test cells in shifts: high-precision calibration during the day and long-duration durability runs overnight. This schedule doubles the utilization of the equipment and improves cost-efficiency for customers.
Integrated Power Management and Regeneration
Modern EV test benches are bidirectional by necessity. They must deliver power to the unit under test (UUT) and also recover power from regenerative braking simulations. Unico’s SiC-based drive cabinets are designed with this principle in mind. They utilize a central DC bus architecture that enables recirculation of power between battery emulators and dynamometers.
Instead of taxing the grid, the system reuses power internally. Only the system losses—rather than full test power—are drawn from the utility. This design greatly reduces operational costs and supports scalability. With power-hungry tests becoming more common, especially with high-voltage systems like the Cybertruck or Lucid Air (often running at 800–900V), this efficiency is not just beneficial—it’s essential.
Toward a DC Microgrid Future
UTAC and Unico are eyeing the next evolution: facility-wide DC microgrids. By feeding multiple test cells from a central energy storage unit and active front end, facilities can reduce the need for oversized grid connections—an increasingly significant barrier for new test labs.
Imagine a scenario where durability test cells, inverter calibration bays, and battery simulators all pull from a shared DC backbone powered by renewables or large storage systems. This not only improves energy usage but also simplifies electrical infrastructure, making rapid scale-up possible for growing EV programs.
Battery Emulation: Smarter, Safer, Faster
Battery emulators are central to this entire system. Rather than relying on real batteries—which bring complications like safety protocols, limited test cycles, and charge management—UTAC uses parameterized emulation to simulate actual pack behavior.
These Unico emulators can mimic state-of-charge voltage curves, thermal behavior, and even degraded performance profiles. This flexibility allows engineers to validate inverters under realistic constraints, and even pre-integrate powertrain systems before real battery packs are available.
Moreover, Unico’s harmonized system design—housing emulators, drives, and dynos in unified cabinets—ensures seamless communication and rapid test turnaround. Unlike systems where each component must coordinate over separate controls, this integrated approach reduces fault risks and increases uptime.
End-to-End System Delivery and Commissioning
Before a test bench ever reaches a customer, it’s fully assembled and validated at UTAC’s integration facility. Each configuration—from high-speed e-motor stands to full e-axle simulators—is verified for vibration resistance, thermal control, and torque-speed response. Once shipped and installed, commissioning typically takes three to four weeks, depending on complexity.
Clients demand flexibility, not fixed-functionality. As Harrison points out, a test bench today must be adaptable enough to handle next year’s drivetrain architecture. Whether testing a single inverter, a complete e-axle, or even four independent dynos, UTAC’s systems are built to evolve.
The Future of EV Testing Is Modular, Efficient, and Intelligent
UTAC and Unico’s collaboration signals where the EV testing world is headed: toward modular, regenerative, and software-defined systems. By leveraging silicon carbide drive technology, DC microgrids, and battery emulation, they are crafting high-fidelity test environments that mirror real-world use without overloading physical infrastructure or budgets.
For EV developers, this means shorter development cycles, reduced test costs, and more confidence in the performance envelope of their vehicles. And for energy-conscious engineers and executives, it points toward a more sustainable, future-proof testing ecosystem.
Explore More With Munro
Want to see how your team can cut cost, reduce cycle time, and improve product confidence through smarter test benches? Contact Munro & Associates today for a tailored consultation and explore how we can help you drive EV innovation from concept to reality.