Electrification is firmly established in all mobility sectors and continues to grow. As an integral part of complete systems, electric motors must be thoroughly tested for manufacturing defects before further integration. This proactive approach significantly minimises the risk of production problems later in the process. To succeed in a competitive market, manufacturers need to adopt more efficient test methods that can cope with increasing production volumes - achieving faster results at lower cost, while reducing 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.
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 |
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.
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
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.
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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.