AVL E-Motor TS™ Durability

24/7 Performance for Maximum Durability.

The e-motor durability testbed is an advanced test system for e-motors, enabling simultaneous testing of two units. Its intelligent automation and precise emulation ensure reliable performance assessments under extreme conditions, optimizing electric propulsion system efficiency.

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As electrification continues to experience rapid growth, the reliability and durability of electric propulsion system components has never been more important. Ensuring the longevity and consistent performance of these components is essential for manufacturers aiming to stay ahead in the competitive EV market.  A comprehensive durability testing infrastructure is one of the key factors in ensuring that electric motor systems can withstand the rigours of real-world conditions.

The AVL E-Motor TS™ Durability system provides an advanced solution for testing and evaluating electric motors under demanding conditions. Key features include:

  • Reliability, availability, maintainability, and durability evaluations
  • Environmental tests under cold and hot conditions
  • Mileage accumulation
  • Cold start and warm-up procedures
  • Monitoring of production batch tolerances.

By utilizing advanced durability testing methods, manufacturers can ensure their electric propulsion systems meet the highest standards of performance and reliability, supporting the growing demands of the electrification market.

Enhance the reliability and durability of your electric drive system with the AVL E-Motor TS™ Durability. Our advanced testing solution helps you meet fast time-to-market goals while ensuring top performance.

Our system provides a full suite of assessments, including reliability, availability, maintainability, and durability evaluations. It also supports environmental testing in extreme hot and cold conditions, ensuring your e-motors perform under real-world climate challenges. Additional test capabilities include long-term mileage accumulation testing to measure durability over extended use, cold start and warm-up procedure testing to ensure efficient operation at different temperatures, and accurate monitoring of production batch tolerances to maintain manufacturing quality.

By using this system, you can produce highly reliable and fully functional electric motors without the high cost and maintenance of traditional road testing. 

durability

Revolutionize Electric Motor Testing with Advanced Durability Solutions

The AVL E-Motor TS™ Durability system revolutionizes the testing process by enabling the simultaneous evaluation of two units under test in parallel. This innovative approach significantly enhances efficiency and reduces overall testing time.

Key features of the AVL E-Motor TS™ Durability system include:

  • Intelligent AVL PUMA 2™ automation system with machine learning technology
  • Highly accurate battery emulator
  • Precious coolant conditioning system and optional climatic chamber
  • Mechanics with frame, intermediate bearing and mounting systems
  • High frequency AVL X-ion™ power analyzer
  • Baseline measurement for temperature, voltage, and current measurements
  • Testbed safety monitoring system

By incorporating these advanced features, the AVL E-Motor TS™ Durability system enables manufacturers to conduct thorough and efficient testing of electric motors.

Property Unit

Max. Speed

up to 25,000 rpm

Max. Torque

up to 1000 Nm

Coolant Temperature Range

–40 to 130°C

 

AI-Powered Automation System

Detect and react to trends, deviations, or any kind of anomaly by continuously validating data.

Future-Proof Test System

Proven mechanics for UUT speeds of up to 25,000 rpm.

Modular Approach

Upgradeability with coolant conditioning, climate chamber, more powerful DC supply, power analyzer, and torque flange.

Cost-Efficient Test System

Unlike an e-motor testbed where only one e-motor is tested, our back-to-back testbed tests two e-motors simultaneously.

AVL SPECTRA™ Universal Inverter AVL PUMA 2™ E-Motor AVL X-ion™ e-Power AVL E-STORAGE™ Media Conditioning Systems Climatic Chamber Portfolio
Using the Universal Inverter in the Development Process
AVL SPECTRA™ Universal Inverter

As the e-drive system development and validation process shortens, testing e-motors and inverters separately before final system tests is crucial. A universal inverter is needed to validate e-motor performance, dynamics, and thermal characteristics beforehand. For realistic results, the universal inverter’s control properties must mirror those of the final inverter. The AVL SPECTRA™ Universal Inverter uses advanced SiC MosFET technology to support a wide range of switching frequencies and emulate various traction inverters. Featuring an integrated FPGA control unit, it manages all control and emulation tasks and is available as a mobile or cabinet version.

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AVL PUMA 2™ E-Motor

The AVL PUMA 2™ E-Motor is a leading automation system for e-motor testing, offering an exceptional user experience and easy customization. With high-precision speed control and advanced vehicle simulation, this innovative platform utilizes machine learning for real-time data analysis. By adapting dynamically to test conditions, it enhances accuracy and reliability while streamlining the testing process.

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X-ion V7
AVL X-ion™ e-Power

The AVL X-ion™ Power Analyzer delivers precise measurements of power consumption, enabling detailed analysis of motor performance across various load conditions while accurately capturing transient responses. As a modular data acquisition platform optimized for electric and hybrid applications, it offers exceptional flexibility and automotive-inspired testing functionality, making it ideal for the development of electrified powertrains.

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e-storage sic
AVL E-STORAGE™

AVL E-STORAGE offers a versatile range of testbed configurations, allowing for efficient and resource-conscious testing. From battery testing and emulation to evaluating entire electrified powertrains, the E-STORAGE family provides comprehensive, flexible solutions. As demand for electric powertrains grows, flexible and future-proof equipment becomes essential. The AVL E-STORAGE SiC represents a significant advancement in testing technology, providing scalable solutions from 160 kW to multi-megawatt clusters.

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AVL Conditioning Systems
Media Conditioning Systems

To accurately simulate extreme driving conditions, conditioning systems must create extreme media conditions that are essential for effective testing. Testbed efficiency is improved by quickly establishing initial conditions. Oil and coolant conditioning systems enable rapid cooling of the unit under test at the end of each test cycle, allowing more tests, including cold start tests, to be performed in the same time frame.

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Climatic Chamber Portfolio

Our climatic chamber for e-motor testing offers an energy-efficient solution that minimizes chamber space and reduces operational costs while supporting sustainability goals. With a separate air conditioning unit, it allows for precise control of temperature and airflow, ensuring optimal testing conditions for various evaluations. Its compact design facilitates easier installation and maintenance, enhancing cost-effectiveness and versatility.

More on Climatic Chambers for E-Motor Testing

AVL E-Mobility Testing Solutions – Brochure

Tested and Trusted.

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AVL E-Motor Testing Solutions – Brochure

Validate e-motors of different types, speeds, and torques.

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Success Story – “High Performance at Hitachi Astemo”
Innovative e-drive testing solutions from a single source.
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AVL E-Motor TS™ Performance

Optimum view of speed and torque. The test system for developing your unique e-drive.

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AVL E-Motor TS™ NVH

Electrified propulsion systems are a growing part of modern transportation. The changing noise/sound landscape is increasingly demanding modern NVH engineering. At AVL, we have solutions and processes for optimizing the design and quality assurance of interior and exterior vehicle sound.

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AVL E-Motor TS™ EMC

Validate the electromagnetic compatibility of your electric drive with our specialized test system. 

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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AVL PUMA 2™ E-Motor

The best-in-class automation system for e-motor testing.

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