E-Axle Production Testing

New ways in testing – highest efficiency with quality in time.
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Electric drives play a central role in both battery electric vehicles (BEV) and fuel cell electric vehicles (FCEV). As the e-mobility market grows rapidly, manufacturers are faced with increasing industrialization and production volume requirements. In order to meet these challenges and ensure high quality products, state-of-the-art test solutions and intelligent test methods for electric axles are required. AVL supports all project phases from concept to implementation and operation. This applies to passenger cars as well as light and heavy commercial vehicles.

Today, it is a fact that the e-mobility market is established and growing rapidly. The daily increasing production volume must be tested in shorter time and with high efficiency. The drive system of an electric vehicle (EV) consists of several components. An e-axle or electric drive unit (EDU) integrates the electric motor, transmission, and inverter. These components may have already been tested separately. However, the complete e-axle must also be tested to eliminate potential assembly defects. For example, noise, vibration and harshness (NVH) is a key factor in driver satisfaction, especially in the field of e-mobility.

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Manage High Production Volume

Handle high production volume with short takt times and maximum testbed up-time.

Ensure Product Quality

Ensure e-axle quality with minimum investment and operating costs to avoid harming recalls.

Secure Acoustic Performance

Detect acoustic abnormalities reliably before integration into the vehicle.

Specifications

The electrified powertrain and testing requirements are driving the complexity and cost of testing. New solutions are needed to meet these challenges and reduce cost and time-to-market while maintaining quality. With our internal AVL E-Axle development know-how and decades of experience in production testing, we have developed AVL E-Axle test systems for production based on our philosophy of simplicity and robustness. AVL offers dedicated test system solutions for End of Line (EoL), Quality Audit (QA) and Conformity of Production (CoP) test applications:

  • AVL E-Axle TS™ End of Line
  • AVL E-Axle TS™ Quality Assurance
  • AVL E-Axle TS™ Conformity of Production

We support our customers with customized testing processes and appropriate testing solutions, defined by following characteristics:

Wide Power Range

  • Solutions for passenger cars, light-, mid and heavy duty vehicles

  • Standard solutions for power ranges up to 440kW (per wheel)

  • Power ranges above 440kW (per wheel) on request

Flexible Layout

  • Small footprint

  • Brick & mortar or protective enclosure

  • Easy integration into existing production environment

Variable Testing Workflow

  • Preparation: Manually, up to fully automated

  • Handling: Trolley, conveyor, robot or AGV

  • Testing: Manual through match plate or automatically connected

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New Way of Efficiency

Reliable 24/7 operation and highly automated workflow ensures large testing capacity addressing increasing industrialization demands.

Reduced Risk and Cost

Ensure e-axle quality with minimum investment and operating costs and meet SOP schedules with on-time testbed delivery.

Experience Your Solution Long Before It Is Build

Virtual Reality (VR) and Augmented Reality simplify and accelerate project planning, execution, training, and maintenance.

Ideal Partner for a Changing Industry

AVL continues development at the forefront of technology and can incorporate these results into the future-proofed testbeds with a long life.

AVL E-Axle TS™ End of Line

  • Application: Designed to deal with high production volume
  • E-Axle handling: From manual to fully automatic
  • Takt time: Down to 90 sec. whereas typically 2–5 min.
  • Load unit per wheel: Up to 5,000 Nm and 3,000 rpm
    / up to 440 kW
  • DC power source: Up to 1.1 MW / 1,200 V / 2,000 A

AVL E-Axle TS™ Quality Audit/Conformity of Production

  • Application: Aimed for extended test cycles
  • E-Axle handling: From manual to fully automatic
  • Takt time: Typically 15 - 30 minutes
  • Load unit per wheel: Up to 5,000 Nm and 3,000 rpm / up to 440 kW
  • Housing: Brick and mortar or containerized (completely pre-assembled and pre-tested before delivery) solution

Efficient Acoustic Quality Control

  • Robust sensors, accelerometers and microphones for production testing
  • Easy expandable acoustic channels
  • Fully integrated data acquisition and evaluation system
  • Standardized test protocols to assess NVH characteristics under various load and speed scenarios

Solution Integration Into Existing Environment

  • Small footprint
  • Seamless connection to assembly line
  • Flexible system layouts with fence, acoustic housing, brick-and-mortar, and container
  • Pre-installed and fully tested plug-and-play solutions
  • Transferability in case of relocation
  • Facilitates replication in different environments and areas
robert nemeth

At AVL, we see our production testing solutions as an important factor for both an effective production process and high product quality – a major pillar our customers can rely on.”

– Robert Nemeth, Department Manager, AVL List GmbH

AVL Production Testing Solutions – Brochure

Quality in Time.

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AVL E-Mobility Testing Solutions – Brochure

Tested and Trusted.

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AVL E-Axle TS™ EOL – Solution Sheet

Test Fast. Judge Confident.

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

Highest Flexibility. Complete Quality.

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Success Story – “Spinning E-Axles”

Quick and lean solution helping TEXA with e-axle industrialization.

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production
Production Testing for E-Mobility

Explore our end-of-line test systems (TS) for production – for e-mobility applications such as batteries, e-axles, e-motors, inverters, and fuel cells.

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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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AVL PUMA 2™ Production

AVL PUMA 2™ Production is our robust automation system designed for production testing of a range of e-mobility applications. 

eMobility Testing
E-Mobility Testing

For every form of e-mobility, we offer in-depth expertise and comprehensive solutions for development, testing, and validation – from component to complete system.

e-motor performance
E-Motor Testing Solutions

AVL has a wide portfolio consisting of dedicated e-motor test systems, software, tools, and processes to test and validate these modern e-drive systems in shortest time and with highest quality standards.

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.

EcoVision Award
AVL received the Global EcoVision Award for achievements in Hungary

AVL List GmbH received the Global EcoVision Award from WKÖ in the presence of Federal Chancellor Karl Nehammer, Federal Minister Martin Kocher, and WKÖ President Harald Mahrer for the achievements in Hungary.

AVL at the 44th Vienna Motor Symposium
AVL at the 44th Vienna Motor Symposium

What kind of cars will we be driving in the future? These and other exciting questions around the topic of "Future Mobility" were addressed by more than 1,000 participants from 25 countries at the international 44th Vienna Motor Symposium. The tenor: Future automobiles will be CO2-neutral.

Honorary Citizenship Helmut List
Helmut List Awarded Honorary Citizen of the City of Graz

For his services, Prof. Helmut List was today awarded honorary citizenship of the city of Graz.

AVL Brain
AVL Records Growth of 18 Percent and Continues to Invest in New and Sustainable Mobility Solutions

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.

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