E-Axle Testing Solutions

Validating Integrated E-Drive Units with Advanced E-Axle Test Systems for E-Mobility Development.

Our e-axle testing solutions ensure precise evaluation of integrated e-drive systems and improve the performance, efficiency and reliability of electric mobility.

E-Axle Test System

Electric drives are key components in both battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs). As innovations advance, inverters, e-motors, and transmissions are increasingly integrated into compact e-axle sub-systems. This integrated design minimizes interfaces and packaging space but significantly increases the complexity of e-drive testing and e-axle validation.

We offer a complete portfolio of e-axle testing solutions, including advanced e-axle testbeds, modular test systems, and smart software tools. Our solutions are designed to test and validate the entire e-axle efficiently and accurately ensuring performance, efficiency, and reliability across all stages of electric powertrain development.

Modern e-axle systems are compact, deliver high power density, and are engineered for maximum efficiency, performance, and drivability. To meet these demands, e-axle test systems must fulfill strict requirements in terms of durability, dynamic performance, and NVH behavior – ensuring not only functional reliability but also a smooth and comfortable driving experience.

Advanced e-axle testing must also address the growing complexity of electric mobility. This includes supporting predictive maintenance strategies, performing in-depth diagnostics, and adapting to changing test requirements. By enabling precise monitoring and fast response to potential issues, e-axle testbeds help minimize downtime and ensure long-term reliability across the entire lifecycle of the integrated e-drive system.

History
Performance – Light Duty Performance – Heavy Duty Energy Flow Testing NVH Testing EMC Testing Production Testing
E-Axle Performance Testbed for Light Duty Application

Performance Testing – Light Duty

The AVL E-Axle TS™ Performance is a tailor-made solution for the development and validation of light-duty e-axles, whether single or dual motor. With the shortest lead times, you can quickly start life cycle and thermal endurance testing, as well as electrical, mechanical and thermal property analysis. This test system enables precise performance and functional testing up to 20,000 rpm and 400 kW, supported by a direct drive dynamometer, flexible multi-channel cooling conditioning and a climatic chamber for environmental simulation.

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AVL E-Axle Performance Test System – Heavy Duty

Performance Testing – Heavy Duty

The AVL E-Axle TS™ Performance - Heavy Duty is a standardized test system designed for the development and validation of e-axles in commercial vehicles. It enables comprehensive life cycle testing under realistic vehicle-like conditions and supports precise performance and functional testing with over 800 kW of power. Two compact wheel load machines, each with a peak torque of 40,000 Nm, and an optional temperature chamber with multi-channel cooling to simulate climatic environmental conditions ensure that e-axles can be tested optimally under a wide range of operating conditions.

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Overview of the energy flow testbed

Energy Flow Testing

This innovative solution enhances efficiency and optimizes performance through comprehensive testing and validation. It includes electrical range evaluation under various climates, system efficiency validation, energy management during driving, recuperation, and charging. Additionally, it covers strategy verification, road tests, failure mode analysis, EDU performance optimization, and evaluation of electrical auxiliaries and recuperation techniques.

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E-Axle NVH Testbed - open view

NVH Testing

Our AVL E-Axle TS™ NVH system is designed to redefine silence, comfort, and overall performance in both light-duty and heavy-duty e-axle solutions. With exceptionally low operating noise levels, it ensures superior NVH performance. The system features semi-automatic track width and wheelbase adaptations, enabling high-end NVH development with ease. This innovative solution is setting new industry standards for NVH engineering in both current and future e-powertrains, ensuring optimal performance and maximum user comfort and satisfaction across all mobility applications.

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E-Axle EMC Test System

EMC Testing

To measure the electromagnetic compatibility (EMC) of e-drive systems and evaluate their emissions or assess their immunity to interference, specialized EMC test systems are required. Our AVL E-Axle TS™ EMC provides precise measurements and testing in accordance with the CISPR 25 standard, ensuring your systems meet stringent industry regulations. With this solution, you can effectively assess both emissions and immunity of your e-axle components, guaranteeing the reliability and compliance of electric drive systems for future mobility applications.

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E-Axle Production Test System

Production Testing

Our End-of-Line (EOL), Conformity of Production (COP), and Quality Assurance (QA) test systems are designed to ensure the quality and security of your entire e-axle production process. These fully automated e-axle rigging systems, integrated with robotic handling, allow for extremely short takt times, reducing them to just 120 seconds. By incorporating these advanced testing solutions into your production line, you can achieve high throughput while ensuring the highest quality standards, improving both the efficiency and reliability of your e-axle manufacturing process.

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With our in-house engineering expertise, we actively analyze market trends and drive innovation to provide our customers with the best possible support. Based on this deep application know-how, we develop e-axle testing solutions that help our customers achieve their development goals”

Reinhard Merl, Global Business Segment Manager, AVL List GmbH

Our pre-engineered e-axle testing solutions are designed to minimize Total Cost of Ownership (TCO) while meeting strict requirements for service lifetime, NVH, and EMC compliance. With a compact footprint and low energy demand, they support efficient use of space and resources.

To maximize operational efficiency, our solutions enable faster test cycles and seamless integration into existing automation environments for fully automated testing. By significantly reducing grid power consumption, they contribute to lower environmental impact and support sustainable, energy-efficient testing operations.

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AVL E-Mobility Testing Solutions – Brochure

Tested and Trusted.

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AVL E-Axle TS™ Performance - Light-Duty – Solution Sheet

Integrated perfection.

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AVL E-Axle TS™ Performance Heavy-Duty – Solution Sheet

A smarter way of testing e-axles.

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AVL E-Axle TS™ NVH – Solution Sheet

Our commitment to silence.

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AVL E-Axle TS™ QA / COP – Solution Sheet

Highest Flexibility. Complete Quality.

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Tech Center Module – AVL E-Axle TS™ – Solution Sheet

The fast lane to ramp up e-axle testing.

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Automation & Control for E-Axle Testing – Solution Sheet

Highly efficient automation and control for e-axle testbeds.

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AVL offers comprehensive software solutions to optimize your e-axle testing performance. Our holistic approach combines lab efficiency through automation and test optimization via virtualization for faster results.

The advanced data analytics solution using AI extracts valuable insights from various sources. Additionally, our solutions are designed to seamlessly integrate with your existing systems, ensuring a smooth transition.

This will help you get your products to market faster while ensuring high-quality performance. Learn more about AVL’s approach and explore our software solutions to optimize your e-axle testing process now.

E-Axle NVH Testbed - Setup
AVL E-Axle TS™ NVH

AVL’s deep experience with NVH powertrain testbeds allows to provide a high-quality acoustic test environment for e-axles. All components and acoustic enclosures are designed by AVL to ensure excellent NVH performance with minimal sound reflections through simulation-optimized design. 

E-Axle Production Test System
E-Axle Production

Based on years of experience in research and development, as well as production, we have developed AVL E-Axle TS™ Production. It provides End of Line (EOL) and Conformity of Production (COP) testing for electric drive applications, from passenger cars to high performance vehicles, as well as industrial applications.

Tech Center Modules
AVL Tech Center Modules

Customer requirements show the need for additional test capacity for ambitious product development plans. AVL Tech Center Modules significantly shorten this process. The flexible, location-independent and easily relocatable modular test system is particularly helpful.

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AVL PUMA 2™

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.

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AVL PUMA 2™ Machine Learning

Intelligent automation, quick and easy

AVL Cameo 5
AVL CAMEO 5™

AVL CAMEO 5™ unlocks a new maturity level of calibration and validation in automotive software testing. 

Customer Services
Customer Services for Testing Solutions

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.

Your reliable partner in powertrain and e-axle testing solutions

AVL’s comprehensive worldwide network of experts allows best customer vicinity, ensuring consistent and connecting testing fields globally. Wherever your R&D challenges take you, we are always close at hand, ready to provide the service you need.

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> 30

years of experience.

> 4,000

powertrain experts.

> 500

executed powertrain and e-axle projects.

> 45

global technical and engineering centers.

See what drives us and explore our latest developments
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AVL at the 44th Vienna Motor Symposium
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For his services, Prof. Helmut List was today awarded honorary citizenship of the city of Graz.

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AVL generated 1.86 billion Euros in turnover last year – Eleven percent flows into research and development – 60 percent of the turnover is already generated by new technologies.