About the EU automobile industry

12.9 million Europeans work in the automotive sector

8.3% of all manufacturing jobs in the EU

€392.2 billion in tax revenue for European governments

€101.9 billion trade surplus for the European Union

Over 7% of EU GDP generated by the auto industry

€59.1 billion in R&D spending annually, 31% of EU total

Europe dominates the global market for test automation systems for powertrain dynamometers because of the region's concentration of major automakers, strict vehicle safety and pollution laws, and R&D centers. Additionally, the expansion of the motorsports sector and motorsports-related events like circuit racing and rallycross will support regional growth. Test automation systems for powertrain dynamometers are in higher demand as a result of the teams' enhanced testing of their vehicles at these motorsports events. In October 2023, EU registrations of battery-electric cars increased significantly, growing by 36.3% to reach 121,808 units. Several markets contributed to this expansion with triple-digit percentage increases, particularly Belgium (+147.3%) and Denmark (+100.7%). Following a slowdown in September, Germany – the largest market for battery-electric cars – grew modestly (+4.3%) in October. This brings the year-to-date volume to 1.2 million units, marking a noteworthy 53.1% gain compared to last year and capturing a 14% share of the EU car market over the ten-month period.

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The European Union launched a strong push on the transition to EVs through the Green Deal Industrial Plan, released in February 2023, and political agreement on the Alternative Fuels Infrastructure Regulation that will mandate member states to roll out public charging for light- and heavy-duty vehicles. Political agreement has also been reached on a law that will mandate the adoption of low-emission alternatives to fossil-derived jet kerosene in aviation, as well as low-emission fuels in maritime. A proposal to revise the EU’s Emissions Trading System (ETS) to cover maritime emissions, and create a separate new ETS that also includes road transport emissions, is being formulated.

In 2021, the Dutch government and CALSTART’s Drive to Zero Campaign launched the Global Memorandum of Understanding (MoU) on Zero-Emission Medium- and Heavy Duty Vehicles, through which signatories commit to work together to achieve 100% ZEV bus and truck sales by 2040, with an interim goal of 30% by 2030.

In 2022, 11 countries signed the MoU, bringing the total number of countries and territories among the signatories to 27. These account for over 15% of total annual sales of new medium and heavy-duty vehicles worldwide.

Quick Facts:

The new legislation sets the path towards zero CO2 emissions for new passenger cars and light commercial vehicles in 2035. Intermediate emissions reduction targets for 2030 are set at 55% for cars and 50% for vans.

EU ban on the sale of new petrol and diesel cars from 2035, from 2035, all new cars that come on the market cannot emit any CO2. This is to ensure that by 2050, the transport sector can become carbon-neutral.

Norway continues to lead in terms of sales share of electric cars, reaching nearly 90% in 2022.

The state of the market for EV powertrain testing could be seen as buoyant at the moment, as the automotive industry transitions from IC engine test capabilities to those that support new and future propulsion systems centred on electrification and other alternatives to fossil fuels, such as hydrogen. The EU’s ban on the sale of new petrol and diesel cars from 2035 is giving a transformation already under way further impetus and urgency. Vehicle and equipment manufacturers are developing the required test methodologies and capabilities, while service providers are transforming their offerings to support the needs of the new powertrain technologies. One provider of test services for rotating machinery reports that its teams is working almost entirely on fully electric vehicles and “not even on hybrids any more”.

Testing essentials:

EV powertrains are characterised by high-speed, high power-density input machines, with integrated gearbox systems that deliver high wheel torque from zero speed, explains a global engineering consultancy and services provider, which offers EV powertrain system design, development, integration, testing and validation of components as well as complete vehicles.

The company can test e-machines on single-axis test rigs, gearbox systems on input-output rigs and electric drive units (EDUs) on 2WD and 4WD powertrain rigs.

The expert says test systems must be able to match the high performance of modern EV powertrains while being durable enough to deliver repeated test campaigns. “Performance and efficiency are important factors for EV powertrain, requiring highly accurate torque measurement and power analysis systems that look at both the DC and AC systems.”

A basic test system consists of a high-speed dynamometer or a pair of wheel-speed dynos integrated with a battery simulator, the variable-speed drives and controls systems provider. The simulator is needed because EV powertrains are normally tested without their batteries.

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Powertrain testing is complex, and typically follows the V model, in which the ‘V’ stands for verification and validation while also evoking the shape of the letter as an aid to visualising the flow of a development process and the relationship between the engineering and testing phases. The engineering phases run down the left side of the V from top to bottom, progressing from user requirements engineering through system requirements engineering and architecture engineering and design down to fabrication of hardware and coding of software. On the right, the testing phases flow from bottom to top, from unit testing through subsystem integration testing then system integration testing, then system testing and finally acceptance testing. Each testing phase verifies and validates the work done in the corresponding engineering phase on the opposite stroke of the V.

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Conclusion

Europe dominates the global market for test automation systems for powertrain dynamometers because of the region's concentration of major automakers, strict vehicle safety and pollution laws, and R&D centers. Additionally, the expansion of the motorsports sector and motorsports-related events like circuit racing and rallycross will support regional growth. The European Union launched a strong push on the transition to EVs through the Green Deal Industrial Plan, released in February 2023, and political agreement on the Alternative Fuels Infrastructure Regulation that will mandate member states to roll out public charging for light- and heavy-duty vehicles. The state of the market for EV powertrain testing could be seen as buoyant at the moment, as the automotive industry transitions from IC engine test capabilities to those that support new and future propulsion systems centred on electrification and other alternatives to fossil fuels, such as hydrogen. The EU’s ban on the sale of new petrol and diesel cars from 2035 is giving a transformation already under way further impetus and urgency. The expert says test systems must be able to match the high performance of modern EV powertrains while being durable enough to deliver repeated test campaigns.

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