Electrification is firmly established in all mobility sectors and continues to grow. Electric motors, as an integral part of these systems, must undergo thorough testing for manufacturing defects before integration. This proactive approach significantly reduces the risk of production problems in later stages.
To remain competitive in the market, manufacturers need to adopt more efficient testing methods. These methods must handle increasing production volumes while ensuring faster results, lower costs, and reduced 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 and ensure product quality.
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.
Leveraging our extensive expertise in R&D and production testing, we have developed a highly reliable and robust test system that improves product quality assurance (OK/NOK) for electric motors. This innovative system streamlines test processes, significantly reducing test time and total cost of ownership.
Unlike conventional e-motor end-of-line (EoL) testing solutions, our system eliminates the need for a dyno, e-motor cooling and traditional current, voltage and power measurements by measuring forces directly. The entire process - from mounting the e-motor to completing the test - takes less than a minute and delivers results at a fraction of the cost.
| 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 |
Minimized Testing Time
A predefined test with less than 60 sec test time provides a complete data set for the holistic evaluation of the e-motor, and all that fully automated for 24/7 operation.
New Level of Quality Evaluation
Direct force measurement with fix installed sensors provides highly reproducible and reliable test results.
Reduced Risk and Cost
Ultra-compact, standardized design and absence of dynos and electric motor cooling significantly reduce investment, operating and maintenance costs compared to conventional test systems.
Flexible and Future Proof
Highly standardized and scalable solution enables fast and cost-effective test system adaptation to address increasingly growing number of e-motor variants.
Our patented test system uses piezoelectric crystal sensors to evaluate e-motor performance. Mounted on a dynamic force sensor plate, the e-motor undergoes quality checks by measuring forces during a load-free predefined test. This enables the assessment of critical parameters like cogging torque, torque ripple, imbalance, bearing forces, friction, NVH, and more. Additionally, the system provides real-time data analysis to ensure immediate feedback and precise adjustments.
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 with other production data to determine optimization potential for the entire production line and the product design.
Quality will decline if it is not continuously improved, at least at the speed at which technology advances. Our innovative measurement method opens up new ways of fault detection and data evaluation for testing e-motors in all industries. AVL E-Motor TS™ EoL Unloaded significantly improves quality through fast and reliable testing.
– Ferdinand Mosbacher, Senior Solution Engineer, AVL List GmbH
AVL Production Testing Solutions – Brochure
Quality in Time.
AVL E-Mobility Testing Solutions – Brochure
Tested and Trusted.
AVL E-Motor TS™ EOL Unloaded – Solution Sheet
Quality by Forces.
Production Testing with Big Data – Whitepaper
How to Turn Production Testbed Data into Valuable Insights with AI
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 meet the special requirements in production testing, we offer a specialized portfolio.
AVL PUMA 2™ Production is our robust automation system designed for production testing of a range of e-mobility applications.
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.
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.