E-axles for commercial vehicles feature integrated subsystems like e-motors, inverters, transmission, and differential for optimal efficiency and minimal size. Traditional isolated testing of these subsystems is no longer feasible due to their interconnectivity. Hence, modern e-axle test systems must meet testing standards for all electrical and mechanical subsystems, enabling cross-functional testing regarding performance, reliability, and thermal endurance to save time and costs during service lifetime analysis of e-axles.
AVL's E-Axle TS™ Performance – Heavy-Duty was developed upon these criteria and represents a comprehensive solution, broadly positioned in terms of testing capabilities, with a seamlessly integrated automation system for efficiently executing various testing tasks. It is standardized and easy to install, ensuring productivity without significant cost impact, making it an intelligent choice for cost-effective testing strategies.
Minimized TCO
Standardized and pre-engineered solution to be productive in testing as soon as possible.
Increased Efficiency
Testing processes must be efficient to meet development timelines and contain costs while maintaining high-quality standards.
Rising Complexity
Need for a comprehensive test system with a seamlessly integrated automation system.
Standards Compliance
Rigorous testing standards for all electrical and mechanical subsystems must be fulfilled.
Our e-axle test system offers specialized testing under vehicle-like conditions, featuring a reliable load system with two compact torque motors, specifically developed for this application. These meet common torque, speed and power requirements for commercial vehicles without the need for damage-prone and maintenance-intensive reduction gearboxes. The specific test system frame minimizes the footprint to an optimum and eliminates the need for complex facility structures, through which the test system is cost-effective and versatile for common industrial floors. Furthermore, a modular e-axle rigging system ensures easy assembly of the respective test objects. Optional features include a climatic chamber for thermal conditioning of e-axles.
The technological features described make our test system to a powerful instrument for testing e-axles, streamlining efficient as well as realistic analysis regarding performance, reliability and thermal endurance, consistently ensuring high productivity during all testing tasks.
| Load System | per Wheel |
| Max. Power | 625 kW |
| Max. Speed | 1,250 rpm |
| Max. Torque | 40,000 Nm |
| DC Source | |
| Max. Power | 550 – 1,100 kW |
| DC Output Voltage | 20 – 1,200 V |
| Max. Current | 2,000 A |
| General | |
| E-Axle Types | Rigid e-axles |
| Max. E-Axle Width | 2,600 mm |
| Dimensions (W x D x H) | 8,000 x 1,700 x 2,450 mm |
AVL Automation
Our advanced automation system, AVL PUMA 2™, adapts easily to modern testing methods, maintaining consistent and transparent testbed configurations. With streamlined parameter configuration and immediate validation, PUMA 2™ minimizes testbed downtime and maximizes output and efficiency, particularly for complex calibration tasks.
AVL Testbed.CONNECT™
Simulation is the key to effective frontloading. To support our customers in achieving this, we have created Testbed .CONNECT™, a powerful and open execution platform that connects simulation models to the testfield.
AVL Climatic Chamber
Components like e-axles require resilience to diverse environmental conditions, spanning arctic winters to hot tropical summers, with humidity affecting performance and lifespan. Climate chambers facilitate testing to meet standards, including accelerated lifetime tests through thermal shocks.
From customer project insights, we developed a test system unlocking the full potential of e-axle testing. This empowers our customers to efficiently execute their testing strategies, and successfully bring their e-axle developments to life.”
– Christian Wooning, System Line Manager, AVL Deutschland GmbH
At AVL, we develop e-axle solutions that can be easily installed without impacting the productivity of your engineering facility.
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.
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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.
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