The e-drive system is pivotal to the satisfaction of both drivers and passengers in electric vehicles (EVs), as it is central to delivering an exhilarating driving experience. Modern e-drive systems are engineered to be compact with high power density, optimized for efficiency, performance, and drivability.
Additionally, these systems must adhere to strict Noise, Vibration, and Harshness (NVH) requirements to ensure a smooth and comfortable ride. Compliance with rigorous Electromagnetic Compatibility (EMC) standards is essential for vehicle safety. Moreover, the robustness of the e-drive system is critical to meeting longevity and durability requirements throughout its operational lifespan.
Developing e-motors with high power density and efficiency is crucial for modern automotive drives. It is equally important to ensure first-class driving characteristics in terms of comfort, economy and sportiness. The AVL E-Motor TS™ Performance is designed to unlock the full potential of your e-motor and inverter. Its advanced mechanics and dynamometer design provide reliable testing at high speeds with precise control accuracy in both stationary and dynamic conditions. Our state-of-the-art software tools provide comprehensive solutions for tuning, analysis, and validation. Achieve fast, powerful, and reliable test results with our proven software tool chain.
The increasing complexity of noise and sound in modern powertrains requires advanced NVH technology. Our expertise in high-speed applications and NVH testing has led to the development of a comprehensive portfolio of standard NVH test system solutions. The AVL E-Motor TS™ NVH offers customization to meet the specific needs of each customer. We focus on creating development environments that efficiently address NVH challenges with a range of solutions categorized into Premium, Precision, and Efficiency setups. These options ensure that we can meet diverse requirements while increasing development speed and sustainability.
Managing electromagnetic emissions and interference is critical for modern vehicles equipped with advanced communication interfaces. Our solutions comply with the latest EMC standards and allow comprehensive assessment and validation under real-world conditions. Our test solutions provide mobile capabilities for full-load EMC testing in existing chambers, minimizing the need for modifications. This mobility facilitates efficient setup and transfer, while our fixed and modular systems ensure uncompromised torque and speed during testing. Our solutions provide a fully equipped environment for e-motor development, ensuring optimal performance of electronic systems.
Increase the reliability and durability of your electric drive system with AVL E-Motor TS™ Durability. This solution is designed to accelerate time-to-market goals by covering a wide range of assessments, including reliability, availability, maintainability, and durability. It supports environmental testing at extreme temperatures and evaluates accumulated mileage, cold start, warm-up, and production batch tolerance. By enabling reliable production of e-motors without extensive road testing, our innovative procedures accelerate mileage accumulation, reduce overall test time, and lower handling costs.
As the e-mobility market expands, manufacturers face increasing demands for industrialization and production volumes. To meet these demands, reliable and future-proof solutions are essential. We support every project phase, from concept to operation, with a comprehensive production test portfolio. Our solutions include loaded and unloaded end-of-line testing, quality audit and conformity of production testing. This approach ensures robust production processes and high quality standards for all produced e-motors, safeguarding your manufacturing operations and increasing product reliability.
An e-motor testbed must meet many requirements to ensure a fast and reliable test process. Effective testing of units under test across multiple performance levels - such as power, current, voltage, speed, and torque - is essential.
Our best-in-class automation and control system offers outstanding user experience, easy customization and unique features like high-precision speed and position control. The automation system is enhanced with AI capabilities enabling users to take full advantage of machine learning algorithms during the development process. AVL PUMA 2™ Machine Learning allows to detect anomalies in the setup, e.g. increased vibrations, at an early stage, preventing potential damage to the unit under test and saving valuable time.
AVL’s e-motor testing solutions can handle a variety of e-motor types, including Permanent Magnet Synchronous Motors (PMSM), Asynchronous Motors (ASM), and Externally Excited Synchronous Motors (EESM).
AVL’s e-motor testing systems offer precise, efficient, and reliable evaluation of electric drive systems. They help accelerate development, validate performance, address NVH (Noise, Vibration, and Harshness) challenges, ensure EMC (Electromagnetic Compatibility) compliance, and ensure durability and production quality.
Yes, AVL’s e-motor test systems can be used in various industries beyond automotive. These systems are versatile and can be applied to mobility sectors such as aviation, rail, marine and stationary sector. Additionally, AVL provides specialized test systems for high-performance applications in motorsport. This flexibility makes AVL’s solutions suitable for a wide range of electric motor testing needs across different industries.
AVL provides a comprehensive portfolio of NVH test systems, including customizable solutions to meet specific customer needs. These systems help manage noise and vibration challenges, ensuring a quiet and comfortable driving experience. AVL offers different standardized test system setups: The Premium Setup achieves the lowest noise at high speed, the Efficiency Setup offers the highest modularity, and the Precision Line enables a complete microphone hemisphere without interference from mechanical surfaces, ensuring accurate sound measurements.
AVL’s EMC test solutions comply with the latest standards (CISPR 25 and ISO 11452-2) and allow comprehensive assessment and validation under real-world conditions. They offer both mobile and fixed testing solutions to ensure e-motors meet EMC standards. The standardized Interface with Rohde & Schwarz R&S®ELEKTRA EMC test equipment automation and AVL PUMA™ testbed automation ensures smart and efficient testing in dynamic real driving conditions with realistic results.
AVL’s state-of-the-art software tool chain provides comprehensive solutions for automation, calibration, analysis, and validation. These software products help achieve fast, powerful, and reliable test results, post-processing and optimizing the overall efficiency of e-motor development. Browse here to learn more: AVL PUMA™, AVL CAMEO™, AVL CONCERTO™, AVL IndiCom™, AVL PUMA™ Machine Learning, Testbed.CONNECT™, AVL ISAC™.
Yes, AVL offers a complete production test portfolio, including end-of-line testing (EoL), quality assurance (QA), and conformity of production testing (CoP). These solutions ensure robust production processes and high-quality standards for all produced e-motors.
AVL’s high-speed e-motor test system can handle performance and function tests up to 60,000 rpm (even up to 125.000 rpm for racing applications). These systems provide precise control accuracy in both stationary and dynamic conditions, supporting the development of high-speed e-motors.
Yes, AVL offers advanced climatic chambers specifically designed for e-motor testing. These chambers can simulate a wide range of environmental conditions, from extreme cold (-40° C) to intense heat (up to +150°C) as well as humidity, ensuring that e-motors are thoroughly tested for durability and performance under various scenarios. The test systems are equipped with advanced safety features to handle critical thermal issues and ensure the protection of both the test components and the surrounding facilities.
AVL’s e-motor testbeds are designed to meet various performance levels, including power, current, voltage, speed, and torque. They are optimized for different technologies and performance metrics, ensuring a fast and reliable test process. What makes the AVL test systems unique, are elements like the AVL SPECTRA™ family with latest Sic technology inside for best dyno performance and control capabilities, tools like the Universal Inverter or the Dynamic Torque Sensor, the holistic software-toolchain including the automation software PUMA, that also covers machine learning, and measurement devices such as AVL X-ion power analyzer including e-motor specific applications.
AVL offers modular test systems (containers) that can be easily scaled up. By adding more test modules, you can increase your testing capacity without significant downtime. Another way to maximize testing is the implementation of AVL’s advanced automations systems PUMA or request a consulting by our support team: They provide on-site assistance, training and maintenance to ensure your test systems are always running at optimal capacity.
We are dedicated to fine-tuning and optimizing our e-motor testbeds, products, and software tools, ensuring they not only excel in e-motor testing but also support our customers in developing the best e-drive systems for their electric vehicles. With a comprehensive portfolio that includes Performance, NVH, EMC, Durability, and Production Test Systems, we provide the foundation to achieve superior e-drive performance.”
– Alban Hemery, Department Manager E-Motor Test Systems, AVL List GmbH
The best-in-class automation system for e-motor testing.
The perfect hardware for AVL’s leading automation system
AVL’s E-Library is a mindful solution that introduces simplicity when dealing with e-testing complexity, provides a fast track to productivity, and offers reassurance that targets will be met – putting your mind at ease and allowing you to enter the market with full confidence.
AVL CAMEO 5™ unlocks a new maturity level of calibration and validation in automotive software testing.
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.
Versatile and easy-to-use inverter emulator improves your e-motor and inverter development and testing processes.
We provide comprehensive and advanced e-motor testing solutions designed to ensure precise, efficient, and reliable evaluation of electric drive systems. Our solutions accelerate development, address NVH challenges, and ensure the quality and durability of e-motors.
The Added Value
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Optimized Testing Efficiency: Our advanced testing systems deliver rapid and accurate evaluation of e-motors, including PMSM, ASM, and EESM, expediting vehicle integration.
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Enhanced NVH Management: Our customizable NVH testing solutions effectively handle noise and vibration challenges, ensuring a quiet and comfortable driving experience.
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Superior EMC Compliance: With mobile and fixed testing solutions, we ensure e-motors meet the latest EMC standards and operate reliably within existing communication systems.
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Advanced Durability Testing: Our Durability system boosts e-motor reliability through extensive environmental and mileage tests, reducing the need for costly road tests.
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Comprehensive Production Testing: Our testing solutions cover all production phases, from End-of-Line testing to Quality Audits, ensuring manufacturing efficiency and product quality.
Thanks to our global e-drive experts, AVL has a holistic know-how in engineering and testing of modern e-motors and Inverters for any kind of electric vehicles. Many of these experts are located in our affiliates and global tech- and engineering centers for customer support and projects.
15
years of experience with e-motor testbeds
> 300
e-motor test systems in use globally
Complete
portfolio, existing of performance-, NVH-, EMC-, durability- and EOL testbeds
45
Affiliates ensure global support
45
Global Tech- and Engineering centers
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AVL List GmbH has appointed Matthias Dank as new board member and Executive Vice President (EVP). The top manager with international experience was previously at McLaren Applied, where he was Director of Motorsport.
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Latest projects from Northrop Grumman and Eviation presented at CES
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AVL RACETECH, the motorsport department of AVL, presents the prototype of an innovative H2 internal combustion engine. The power unit is a compact, hydrogen-powered 2-liter turbo engine, with intelligent water injection, which achieves a totally new performance level. The first racing engine that AVL RACETECH is developing and building in-house.
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