Electrification in all mobility industries has already been established and is continuously growing. The e- motor, as part of a complete system, must be checked for production faults prior to further integration. This drastically reduces the risk of problems at a later stage of production. In order to be successful on the market, the increasing production volume must be tested more efficiently, i.e. faster at lower cost and with lower overall energy consumption.
Manage High Production Volume
Short cycle times, with a small number of reliable test beds.
Ensure Product Quality
Increased reproducibility of test results.
Reduction of Cost
A solution with minimal investment, operation and maintenance costs is required.
Increasing Number of Variants
Fast and cost-effective test system adaptation for continuously increasing e-motor variants.
Based on our know how and experience, both in R&D and production testing, we have developed this highly reliable and robust test system. It significantly improves product quality assurance (OK/NOK), testing time and total cost of ownership. The system requires no dyno, no cooling of the e-motor and even no current, voltage and power measurement with forces being measured directly. It takes less than a minute from start of mounting the e-motor until the test is finished - and all this with significantly lower costs compared to conventional e-motor EoL testing solutions.
| Application | Designed to deal with high and very high production volume in all mobility industries. |
|
E-Motor Handling |
Fully automatic |
| Takt time | Down to 60 seconds |
| Measurement principle | Direct force measurement |
| Signal frequency | Up to 20 kHz |
| Derived measurement values |
Material and assembly defects |
| DC power source | For up to 1,200 V |
| Test cell footprint | About 8 m² |
Piezoelectric Measurement Principle
Our innovative and patented test system utilizes the piezoelectric effect of crystal sensors. The e- motor is mounted on the dynamic force sensor plate with embedded piezo crystal sensors. The quality check of the e-motor is done by measuring the forces during a predefined test without any load. From this, the necessary evaluation parameters such as cogging torque, torque ripple, imbalance, bearing forces, friction, NVH and much more can be assessed.
More Than Just OK/NOK: Reveal Additional E-Motor Phenomena
The piezoelectric matrix makes e-motor phenomena visible in a way never seen before - beyond current, accelerometer and strain gauge technologies. In addition to torque and other conventional signals, even further e-motor phenomena can be derived from the measurement result, i.e. the system solution provides more data than required for a pure OK/NOK evaluation. This data can be used together with other production data to determine optimization potential for the entire production line and even the product design.
We offer a complete portfolio of test systems for electrified powertrains, hybrid and combustion engines. AVL’s End of Line, Quality Assurance, and Conformity of Production testing solutions are supporting you to highly secure your product quality and production process.
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.
To ensure that batteries deliver optimal performance over the longest possible lifetime while meeting strict safety standards, we have developed the AVL Battery TS™ End Of Line. From modules to battery packs, this test system enables battery testing in production. The system covers Conformity of Product (CoP) and Quality Assurance testing.
AVL as preferred partner for fuel cell engineering, simulation and testing is providing beyond that integrated solutions for production testing of fuel cell stacks and complete fuel cell systems.
To meet the special requirements in production testing, we offer a specialized portfolio.
To meet the special requirements in production testing, we offer a specialized portfolio.
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.
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.
For his services, Prof. Helmut List was today awarded honorary citizenship of the city of Graz.
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.