AVL E-Axle TS™ Performance Heavy-Duty

A smarter way of testing e-axles for commercial vehicles.
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The automotive industry for commercial vehicles is embracing a techno-logical shift, with electric powertrains like e-axles gaining prominence for trucks and buses. E-axles offer commercial advantages with fewer components and superior vehicle modularity adaptable for different use cases. Our customers face the challenge of swiftly bringing reliable e-axle products to market while efficiently managing testing across vehicle classes.

Therefore, we introduce our AVL E-Axle TS™ Performance – Heavy-Duty, which can be placed on common industrial floors without requiring a specific test system foundation. Our fully standardized solution features two performant torque motors as load system, facilitating cross-functional testing capabilities under vehicle-like conditions for efficient development and validation of e-axle portfolios.

E-axles for commercial vehicles feature integrated subsystems like e-motors, inverters, transmission, and differential for optimal efficiency and minimal size. Traditional isolated testing of these subsystems is no longer feasible due to their interconnectivity. Hence, modern e-axle test systems must meet testing standards for all electrical and mechanical subsystems, enabling cross-functional testing regarding performance, reliability, and thermal endurance to save time and costs during service lifetime analyses of e-axles.

AVL's E-Axle TS™ Performance – Heavy-Duty was developed upon these criteria and represents a comprehensive solution, broadly positioned in terms of testing capabilities, with a seamlessly integrated automation system for efficiently executing various testing tasks. It is standardized and easy to install, ensuring productivity without significant cost impact, making it an intelligent choice for cost-effective testing strategies.

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Minimized TCO

Standardized and pre-engineered solution to be productive in testing as soon as possible.

Increased Efficiency

Testing processes must be efficient to meet development timelines and contain costs while maintaining high-quality standards.

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.

Specifications

Our e-axle test system offers specialized testing under vehicle-like conditions, featuring a reliable load system with two compact torque motors, specifically developed for this application. These meet common torque, speed and power requirements for commercial vehicles without the need for damage-prone and maintenance-intensive reduction gearboxes. The specific test system frame minimizes the footprint to an optimum and eliminates the need for complex facility structures, through which the test system is cost-effective and versatile for common industrial floors. Furthermore, a modular e-axle rigging system ensures easy assembly of the respective test objects. Optional features include a climatic chamber for thermal conditioning of e-axles.

The technological features described make our test system to a powerful instrument for testing e-axles, streamlining efficient as well as realistic analysis regarding performance, reliability and thermal endurance, consistently ensuring high productivity during all testing tasks.

Load System per Wheel
Max. Power 625 kW
Max. Speed 1,250 rpm
Max. Torque 40,000 Nm
   
DC Source  
Max. Power 550 – 1,100 kW
DC Output Voltage 20 – 1,200 V
Max. Current 2,000 A
   
General  
E-Axle Types Rigid e-axles
Max. E-Axle Width 2,600 mm
Dimensions (W x D x H) 8,000 x 1,700 x 2,450 mm
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Ready for Testing

Short delivery time of only 
8 months after order (EXW).

Versatile Solution

Designed for common industrial floors without requiring a specific test system foundation.

Small Footprint

Compact test system design of only 8,000 x 1,700 mm.

Reliable Load System

Powerful torque motors without requiring damage-prone reduction gearboxes.

AVL Automation

Our advanced automation system, AVL PUMA 2™, adapts easily to modern testing methods, maintaining consistent and transparent testbed configurations. With streamlined parameter configuration and immediate validation, PUMA 2™ minimizes testbed downtime and maximizes output and efficiency, particularly for complex calibration tasks.

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AVL Testbed.CONNECT™

Simulation is the key to effective frontloading. To support our customers in achieving this, we have created Testbed .CONNECT™, a powerful and open execution platform that connects simulation models to the testfield.

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AVL Climatic Chamber

Components like e-axles require resilience to diverse environmental conditions, spanning arctic winters to hot tropical summers, with humidity affecting performance and lifespan. Climate chambers facilitate testing to meet standards, including accelerated lifetime tests through thermal shocks.

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christian wooning

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

AVL E-Mobility Testing Solutions – Brochure

Tested and Trusted.

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AVL E-Axle TS™ Performance – Solution Sheet

Productive testing at your facility seven months after order.

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E-Axle Testing Solutions

At AVL, we develop e-axle solutions that can be easily installed without impacting the productivity of your engineering facility.

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E-Axle Production Testing

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.

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.

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