An e-axle, or e-drive unit, integrates the e-motor, inverter, transmission, and often the differential into a single compact system with high power density. This integration improves efficiency and performance but also poses unique challenges for e-axle performance testing, as the components can no longer be evaluated in isolation.
Modern e-axle testbeds must therefore cover service lifetime, performance, and thermal behavior standards across all electrical and mechanical subsystems. Cross-functional testing under vehicle-like conditions is essential to ensure reliable performance, thermal endurance, and overall system integrity. To reduce development time and cost, e-axle test systems should also offer easy installation with minimal facility impact and the flexibility to adapt to future requirements.
Minimized TCO
Pre-engineered solution to be productive in testing as soon as possible.
Increased Efficiency
Accelerate your productivity with a seamless integration of all tools including the automation system.
Rising Complexity
Need for a comprehensive test system with a seamlessly integrated automation system.
Standards Compliance
Rigorous testing standards for all electrical and mechanical subsystems must be fulfilled.
Performance Testing for Light-Duty
The AVL E-Axle TS™ Performance – Light-Duty is a customizable solution to develop and validate your light-duty e-axle, supporting both single and twin motor configurations. It offers efficient testing for service lifetime and thermal endurance, as well as analyzing electrical, mechanical and thermal characteristics.
The System consists of two dynamometers as load system which are installed on one common frame – no dedicated testbed pit required. A flexible UUT support frame allows quick rigging, reducing testbed downtime, while climatic chambers and conditioning systems enable testing under various conditions. With an integrated DC source in the inverter to reduce grid power needs, the system is pre-tested and ready for containerized installation, enabling rapid testing setup.
Performance Testing for Heavy-Duty
The AVL E-Axle TS™ Performance – Heavy-Duty is designed for specialized testing under vehicle-like conditions. It features a reliable load system with two compact torque motors, specifically developed to fulfill the performance requirements of commercial vehicles. These motors cover the typical torque, speed, and power range without the need for maintenance-intensive reduction gearboxes.
Thanks to its compact frame design, the system can be installed directly on industrial floors without requiring a specific test system foundation. A modu-lar rigging system simplifies UUT handling, while optional climatic chambers support thermal conditioning for in-depth testing. The combi-nation of torque motor technology, scalability, and ease of use makes this system a powerful tool for evaluating performance, durability, and thermal behavior.
Automation Software
Our advanced automation software, AVL PUMA 2™ allows systematic e-axle testing for a wide range of applications. It enables precise measurement and closed-loop control of key parameters such as speed and torque.
Energy Efficiency
Modern converter technology allows the integration of a galvanic isolated DC source to supply the power electronics of the e-axle into one drive cabinet. This reduces footprint and grid connection power.
Environmental Tests
Our climatic chambers and conditioning systems enable testing under different climatic conditions. This is mandatory to fulfill test standards such as HTOE and PTCE in e-drive development.
From customer project insights, we developed a test system unlocking the full potential of e-axle testing. This empowers our customers to efficiently execute their testing strategies, and successfully bring their e-axle developments to life.”
– Christian Wooning, System Line Manager, AVL Deutschland GmbH
Battery packs, modules and cells, fuel cells, e-motor and e-axle solutions must operate safely and reliably in any environment. This can include extreme temperatures and humidity, which cannot be reproduced on the test track or in real test scenarios on the road. This is why we developed the modular AVL Climate Chamber.
Thermal conditions and environment of Units Under Test have strong impacts on real results in driving. For this reason, the thermal simulation must be as exact as possible – which can be achieved via deployment of high performing media conditioning systems.
AVL PUMA 2™ is the global industry standard for testbed automation. It is suitable for electrified testbed types as well as for conventional test environments.
The AVL Customer Services organization consists of more than 700 service- and application engineers worldwide, operating from more than 50 locations. Our global footprint is your local benefit.
In this free, 60-minute webinar, experts from AVL explain how to use optimized test systems to overcome the most significant e-axle and powertrain challenges and shorten development time.
How to minimize the calibration effort of an e-motor or e-axle while improving the quality of your results.
In this recording, Klaus Pfeiffer introduces AVLs latest test solutions for e-powertrain, e-axle and vehicle on e-powertrain.