Electric Motorcycle & E-Bike 2-in-1 Chassis Dynamometer Test Bench (FH-DM002)

One bench for your entire electric two-wheeler and three-wheeler range.

The FH-DM002 tests electric motorcycles, e-bikes, power-assist bicycles, and electric tricycles on a single platform — with automated throttle actuation, automated brake actuation, mid-axle pedal simulation, and six simultaneous performance curves. A 45kW ABB servo roller motor, dual torque sensors (500N·m roller + 200N·m mid-axle), and a 0–200kg adjustable counterweight system cover everything from pedal-assist compliance testing to high-speed electric motorcycle characterization up to 120km/h under load and beyond 150km/h at low torque.

Quick Specs

• Roller servo motor: ABB 45kW, 500N·m rated / 716N·m peak torque

• Mid-axle servo motor: Panasonic 5.5kW, 200N·m, 200rpm

• Torque sensor accuracy: ≤0.5% (100μs response)

• Test speed: 0–120km/h at 1,072N resistance; up to 150km/h+ at low torque

• Inertia simulation: 100–500kg (base inertia 300kg)

• Counterweight: 0–200kg adjustable (cylinder-assisted)

• Throttle actuation: Stepper motor pulse control (automated)

• Brake actuation: Dual pneumatic cylinders per lever, 50kg force sensors

• Roller surface resistance: Up to 1,622N

• Model profile storage: 2,000+

• Standards: GB 24156-2018, GB/T 24157-2017, GB 24158-2018, GB 24155-2009, GB/T 5374/5378/5382-2008

 Table of Contents

1. Why a 2-in-1 Dynamometer Makes Sense for Mixed-Vehicle Manufacturers

2. Overview of the FH-DM002 Test Bench

3. Standards Covered by the FH-DM002

4. Main Test Functions and Applications

5. Design Features of the FH-DM002

6. Technical Specifications

7. How the FH-DM002 Testing Process Works

8. Benefits for Manufacturers and Testing Labs

9. Choosing the Right Multi-Vehicle Chassis Dynamometer

10. Real-World Application Scenarios

11. FAQs for the FH-DM002

12. Related Testing Equipment

13. Get a Quote from Feihong Machine

Why a 2-in-1 Dynamometer Makes Sense for Mixed-Vehicle Manufacturers

Most manufacturers of electric two-wheelers don't make just one type of vehicle. A factory producing electric motorcycles often also assembles power-assist bicycles, e-bikes, or electric tricycles on adjacent lines — with different performance standards, different drivetrain configurations, and different regulatory test requirements for each product category.

The conventional approach is to buy separate test equipment for each category: a high-power chassis dynamometer for motorcycles, a compliance tester for e-bikes, a brake tester for both. This multiplies capital cost, floor space, calibration overhead, and the number of trained operators a facility needs to maintain.

A multi-vehicle chassis dynamometer designed to cover the full category range changes this calculus — but only if it genuinely meets the technical requirements of each vehicle type, rather than offering a compromise that underperforms on all of them. The design challenge is real: an electric motorcycle running at 120km/h under full load imposes fundamentally different demands on a roller system than a pedal-assist bicycle being tested for assist-ratio compliance at 25km/h.

The FH-DM002 addresses this with two independent servo drive systems — a 45kW ABB roller motor for high-speed motorcycle testing and a dedicated 5.5kW Panasonic mid-axle motor for pedal simulation — plus automated throttle and brake actuation modules that remove the operator from the test loop entirely. This is not a single machine with a reduced-specification shared mode; it is a machine with two independent drive systems that each operate to their full specification depending on the test being run.

Overview of the FH-DM002 Test Bench

The FH-DM002 is a rear-axle-loaded, center-axle-driven chassis dynamometer with mid-axle pedal simulation, built for manufacturers and test labs that need to cover electric motorcycles, e-bikes, power-assist bicycles (助力车), and electric tricycles on a single platform.

Two Independent Drive Systems

Roller servo system (ABB 45kW): Applies programmable road resistance to the rear wheel via the roller. Rated torque 286N·m, peak torque 716N·m, rated speed 1,500rpm (120km/h), maximum speed 1,647rpm (200km/h+). The roller surface resistance reaches up to 1,622N — sufficient to simulate steep grades and high-drag conditions for performance electric motorcycles.

Mid-axle servo system (Panasonic 5.5kW): Drives the mid-axle at up to 200N·m and 200rpm to simulate human pedaling input. This is the module that enables pedal-assist ratio testing on e-bikes and power-assist bicycles — a test function that pure motorcycle dynamometers cannot replicate.

Two Independent Torque Sensors

Dual sensors measure torque simultaneously at the roller (500N·m capacity) and the mid-axle (200N·m capacity), capturing both the road-load torque and the pedal-input torque in real time — essential for accurate assist-ratio calculation on EPAC-category vehicles.

Automated Throttle and Brake Actuation

Rather than relying on an operator to apply throttle and brake inputs manually — introducing timing variability that can meaningfully affect acceleration and braking test results — the FH-DM002 uses:

• A stepper motor clamped to the throttle grip to apply and release throttle automatically under computer control

• Dual pneumatic cylinders at each brake lever, with force sensors and pressure regulation, to apply calibrated, repeatable braking force automatically

This means the machine executes throttle application, acceleration ramps, brake activation, and brake release as part of a fully automated test sequence — not as operator-dependent manual actions.

Six Simultaneous Performance Curves

The system plots six characteristic curves in real time throughout the test:

• n = f(T): Speed-torque characteristic

• T = f(n): Load characteristic

• η = f(n): Efficiency characteristic

• P1 = f(n): Input power characteristic

• P2 = f(n): Output power characteristic

• I = f(n): Current characteristic (unique addition vs. FH-DM076)

Drive torque and transmission torque curves are displayed simultaneously.

Standards Covered by the FH-DM002

The FH-DM002 is designed to execute test methods defined under the following Chinese national standards:

Coverage for E-Bike Export Markets

The mid-axle pedal simulation and assist-ratio test function also support testing relevant to:

• EN 15194 (EU EPAC standard) — assist-ratio and max speed compliance for pedal-assist bicycles targeting European markets

• GB 17761-2024 — updated Chinese e-bike standard, where power-assist ratio and speed governance are now more tightly defined

Main Test Functions and Applications of the FH-DM002

High-Speed Performance Tests (Electric Motorcycle)

• Maximum speed test — throttle to maximum, speed at steady state recorded; front wheel clamped, rear wheel on roller

• Road simulation test — rated speed for defined time or distance under programmed road-load resistance

• Acceleration performance test — time to accelerate from one defined speed to another, auto-logged

• Chassis dynamometer constant-speed test — maximum throttle, speed monitored under load

• Constant-speed hill-climb — set speed maintained while roller resistance varies to simulate gradient

• Constant-gradient hill-climb — roller set to fixed torque mode; speed varied to characterize performance at constant simulated grade

• Maximum power test — peak output power identified from P2 = f(n) curve

• 0–100km/h acceleration test — timed run from rest to 100km/h under standardized load

Efficiency & Energy Tests

• Range test — duty-cycle method — follows a defined speed/load duty cycle profile from full charge to depletion; both hardware and software support this method natively

• Range test — constant-speed method — full-charge to depletion run at fixed speed

• Energy consumption per 100km — real-time voltage, current, mileage logging; auto-calculates kWh/100km

• Under-voltage protection test — verifies the vehicle activates protection circuitry at the correct low-battery threshold and can or cannot start as required

• Wheel power test — measures mechanical power delivery at the wheel contact point

Safety & Durability Tests

• Motor temperature rise test — rear wheel mechanically locked; throttle progressively increased while motor temperature curve is monitored in real time

• Current cut-off on braking test — verifies that the vehicle cuts motor current within the required time after brake application (regulatory requirement under GB 24155)

E-Bike and Power-Assist Bicycle Tests

• Pedal-assist ratio test — mid-axle motor simulates human pedal input at defined cadence/torque; system measures the ratio of motor assist torque to pedal input torque across speed range

• EPAC compliance speed test — verifies that motor assist cuts out at the correct speed threshold

Automated Actuation

• Throttle module — stepper motor clamps and rotates the throttle grip automatically; opening and closing ramps are computer-controlled

• Brake module — dual pneumatic cylinders at each brake lever; brake force set via pressure regulator; two 50kg force sensors per lever confirm applied force; cylinder position adjustable in all six directions to fit different lever geometries

Six-Curve Analysis (Real-Time, Simultaneous)

Design Features of the FH-DM002

ABB 45kW Roller Servo Motor with Energy Recovery

The 45kW ABB servo motor delivers 286N·m rated torque and 716N·m peak torque — sized to absorb the full output of high-performance electric motorcycles without thermal limitation during extended runs. Energy recovered from the vehicle's drivetrain is dissipated through a resistor bank, maintaining stable load control throughout the test.

Panasonic Mid-Axle Servo for Pedal Simulation

The independent 5.5kW Panasonic servo drives the mid-axle at up to 200N·m and 200rpm — replicating human pedaling input for assist-ratio and EPAC compliance tests. Speed and torque mode switching allows both constant-cadence and constant-torque pedal simulation profiles.

Automated Throttle Actuation (Stepper Motor)

A stepper motor clamps to the throttle grip via a collar fitting and rotates it under pulse control — applying precise throttle openings and closings according to the test program. Software and hardware interfaces are pre-reserved for integration with external control protocols. This eliminates the single largest source of inter-operator variability in acceleration and max-speed tests.

Automated Brake Actuation (Dual Pneumatic Cylinders)

Each brake lever is engaged by two small pneumatic cylinders — adjustable in all six axes to fit any lever geometry. A 50kg force sensor at each cylinder confirms applied brake force. Brake pressure is set via a pressure regulator, enabling repeatable, precisely calibrated braking across test cycles. This allows the bench to execute GB/T 5382 braking performance tests automatically, without a human operator on the vehicle.

Inertia Simulation (100–500kg)

A base inertia of 300kg is extended to a simulation range of 100–500kg, covering the full mass range of electric motorcycles and loaded e-bikes. This means road-load simulation accurately replicates the acceleration and deceleration behavior of the actual vehicle mass — not just a constant roller inertia.

Cylinder-Assisted 0–200kg Counterweight

A cylinder mechanism applies 0–200kg of adjustable vertical load to the vehicle frame, simulating rider mass. The height of the load point is adjustable from 900mm to 1,100mm to match different vehicle seat heights and rider center-of-mass positions.

Wheelbase Adjustment 900–1,900mm

The front-wheel fixture slides on a guide rail and can be positioned anywhere between 900mm and 1,900mm from the rear roller center — covering wheelbase ranges from compact e-bikes and folding models to long-wheelbase electric motorcycles and electric tricycles without fixture changes.

Dual-Mode Motor Control

The system switches between speed control mode and torque control mode — supporting both the constant-speed hill-climb tests (speed mode) and constant-gradient tests (torque mode) required under GB 24156.

Bi-lingual HMI (Chinese / English)

The dynamic simulation display supports Chinese/English interface switching — making the bench practical for both domestic QC teams and export-market auditors or international customers running acceptance tests on-site.

20° Detachable Access Ramp

A detachable ramp at 20° angle allows easy vehicle roll-on and roll-off. The bench frame is welded square-section steel with anti-slip plate surface and full-perimeter sheet metal enclosure.

Technical Specifications of the FH-DM002

Test Performance Parameters

Roller Servo Motor

Mid-Axle Servo Motor

Torque Sensors

Roller

Fixtures & Physical

Why These Specifications Matter

• 45kW / 716N·m peak torque gives the roller servo enough headroom to absorb full-throttle output from high-powered electric motorcycles during transient events — not just at steady state, where rated torque figures apply.

• 100–500kg inertia simulation is what separates a test bench from a simple roller: simulated inertia determines whether the vehicle's acceleration and deceleration behavior during a test genuinely represents what the vehicle does on the road. Without accurate inertia simulation, acceleration time data is meaningless.

• 1,622N maximum surface resistance covers the road-load forces experienced by a loaded electric motorcycle on a steep urban grade — not just flat-road cruising conditions.

• Dual torque sensors (roller + mid-axle) are essential for assist-ratio testing: the assist ratio is the quotient of motor torque to pedal torque, and both must be measured simultaneously to calculate it accurately.

• Automated throttle and brake actuation removes the largest source of test-to-test variability in acceleration and braking tests — enabling compliance-grade repeatability on a production floor, not just in a reference lab.

How the FH-DM002 Testing Process Works

Step 1: Vehicle Mounting and Fixture Setup

The vehicle rolls onto the bench via the 20° ramp. The front wheel is clamped pneumatically; the rear wheel sits on the roller. The front-wheel fixture is adjusted on the guide rail to the correct wheelbase. Counterweight is set to the required test mass. Throttle and brake actuation modules are fitted to the vehicle's grip and levers.

Step 2: Motor Model Selection and Parameter Entry

The operator selects the motor model profile from the stored library (2,000+ profiles) or enters a new model with pass/fail thresholds. Test sequence, inertia simulation value, control mode (speed or torque), and report format are confirmed.

Step 3: Automated Test Execution

Manual button start initiates the sequence. The computer executes throttle applications, acceleration ramps, load changes, and brake activations according to the test program — without further operator input. For duty-cycle range tests, the programmed speed/load profile runs automatically from full charge to depletion.

Step 4: Real-Time Curve Monitoring

Six characteristic curves plot live. The HMI displays all monitored parameters — speed, both torque channels, voltage, current, calculated power, mileage — updated in real time. Out-of-spec results trigger audible and visual alarms; the machine stops automatically.

Step 5: Report Export

All logged data is saved automatically to the operator's profile on completion. Results are exported to Excel in configurable report format. Stored data for all runs is queryable at any time for QC review or certification submission.

Benefits for Manufacturers and Testing Labs

One Platform for the Full Product Range

Compliance-Grade Repeatability from Automated Actuation

Manual throttle and brake application introduces timing and force variability that can produce ±5–10% scatter in acceleration and braking test results across operators. The FH-DM002's stepper-motor throttle and pneumatic brake actuation reduce this variability to the sensor accuracy level — making bench results reproducible regardless of which operator runs the test.

Export Documentation Ready

Six-curve Excel exports, duty-cycle range test logs, and assist-ratio measurement reports are the formats requested by EU and Southeast Asian buyers for pre-purchase technical due diligence — produced directly from the production bench.

Future-Proofed Communication Architecture

Pre-reserved software communication interfaces on both the main and mid-axle servo controllers, the throttle stepper, and the overall software layer mean the bench can be integrated into a factory MES or automated QC reporting system without hardware modifications.

Choosing the Right Multi-Vehicle Chassis Dynamometer

When evaluating a multi-vehicle dynamometer for electric motorcycles and e-bikes, the following questions help identify whether a machine genuinely covers both categories or makes compromises:

Does it have a dedicated mid-axle pedal simulation system?

Assist-ratio testing for EPAC/e-bike compliance requires a separate torque input at the crank — not an approximation via roller resistance. If the machine doesn't have a dedicated mid-axle servo, it cannot accurately measure assist ratio.

Are throttle and brake actuation automated or manual?

For certification-grade braking and acceleration tests, automated actuation (stepper motor throttle, pneumatic brake cylinders) is necessary for the repeatability that regulatory and export documentation requires.

What is the peak roller torque — not just rated?

Rated torque covers steady-state loads. Peak torque determines whether the machine can handle transient full-throttle acceleration of high-power electric motorcycles without the roller motor saturating and introducing load inaccuracy at the critical measurement point.

Does inertia simulation cover the full vehicle mass range?

A dynamometer that cannot simulate inertia — or that simulates it inaccurately — will produce acceleration and range test results that don't correlate with road measurements. Verify the simulation range (100–500kg for the FH-DM002) covers your full product weight range.

Is duty-cycle range testing supported in both hardware and software?

GB/T 24157 and EN 15194 range tests are increasingly specified using a defined duty-cycle speed profile rather than constant speed. Confirm that the machine executes the duty-cycle profile automatically — not as a manually-followed target.

Real-World Application Scenarios

A manufacturer producing both electric motorcycles and pedal-assist bicycles consolidated testing onto a single 2-in-1 platform, reducing total test equipment capital cost while maintaining dedicated test capability for each vehicle category. The automated throttle and brake modules allowed the same bench operators to run motorcycle and e-bike tests without specialized training differences between the two vehicle types.

An export-focused OEM preparing for EU market entry used the assist-ratio test function to verify that their pedal-assist bicycles cut motor assist at precisely 25km/h under the defined pedal torque profile — generating the measurement data required for EN 15194 type-approval submissions without sending vehicles to an external lab.

A quality control lab serving multiple small-volume electric motorcycle clients used the 2,000-model profile storage and dual account system to maintain locked, client-specific QC parameters — preventing any single client's threshold changes from affecting other clients' stored profiles.

FAQs for the FH-DM002 Chassis Dynamometer

What vehicle types can the FH-DM002 test?

Electric motorcycles, e-bikes (battery-assist and pedal-assist/EPAC), power-assist bicycles (助力车), and electric tricycles (where the rear axle is accessible for roller loading).

How does the automated throttle actuation work?

A stepper motor is fitted to the vehicle's throttle grip via a collar clamp. The computer sends pulse commands to the stepper, which rotates the grip to the programmed opening angle — enabling precise, repeatable throttle application and release as part of an automated test sequence.

How does the automated brake actuation work?

Two small pneumatic cylinders are mounted at each brake lever, adjustable in all six axes to fit different lever geometries. A 50kg force sensor at each cylinder confirms applied force. Brake pressure is regulated via a pressure regulator to set the required braking force, and the computer activates the cylinders at the correct point in the test sequence.

What is the difference between duty-cycle and constant-speed range testing?

Constant-speed range testing runs the vehicle at a fixed speed until the battery is depleted — simpler to execute but less representative of real-world use. Duty-cycle range testing follows a predefined speed/load profile (acceleration, cruising, deceleration phases) that better represents typical riding patterns. GB/T 24157 specifies both methods; the FH-DM002 supports both natively in hardware and software.

Can it measure pedal-assist ratio for EPAC compliance?

Yes. The 5.5kW Panasonic mid-axle servo simulates pedal input at defined torque and cadence. The dual torque sensors measure both pedal input torque (mid-axle) and motor output torque (roller) simultaneously, allowing the system to calculate assist ratio across the speed range — the key measurement for EN 15194 and GB 17761 pedal-assist compliance.

What is the current characteristic curve I = f(n)?

This is the sixth curve the FH-DM002 plots — motor current draw as a function of rotational speed. It shows how current demand changes across the operating range, which is important for battery sizing, controller calibration, and identifying operating conditions that risk over-current events.

How is energy recovered from the test vehicle?

Energy absorbed from the vehicle's drivetrain by the roller servo is dissipated through a resistor bank. This maintains stable, consistent load control throughout the test run — particularly important during extended range tests where thermal stability of the load system affects result accuracy.

Does the HMI support English?

Yes. The interface supports Chinese/English switching — useful for international customers running acceptance tests, for export-market auditors visiting the facility, or for factories with multilingual production teams.

What communication interfaces are available?

TPC or RS-485 communication control the main and mid-axle servo motors. Stepper motor throttle control uses pulse interface. All major control points have pre-reserved software interface protocols for integration with external MES or reporting systems.

Related Testing Equipment

• Electric Motorcycle Chassis Dynamometer (FH-DM076) — single-vehicle platform for electric motorcycles; 26kW servo, 500N·m, 0–100km/h; five-curve analysis

• Electric Motorcycle & Unicycle Chassis Dynamometer (FH-DL106) — high-speed platform for performance electric motorcycles and self-balancing unicycles; 64.6kW, up to 160km/h loaded

• Electric Bicycle Comprehensive Test Machine (FH-ZD2988) — max speed, dry and wet braking, range, and power testing for e-bikes per EN 15194, ISO 4210, and GB 17761

• Bicycle Frame Fatigue Testing Machine — structural endurance testing for frames and forks per ISO 4210 and EN 14764

Get a Quote from Feihong Machine

Feihong Machine (Dongguan Feihong Instrument and Equipment Co., Ltd.) designs and manufactures precision chassis dynamometers and performance test systems for electric two-wheeler and three-wheeler manufacturers.

To get started:

• Request a Quote — share your vehicle types, speed range, standards required, and production volume and we'll confirm the right configuration

• Request Technical Datasheet — full mechanical drawings, sensor calibration data, and electrical schematics

• Schedule a Demo — see the FH-DM002 run a live assist-ratio test or duty-cycle range sequence

Request a Quote →