Sourcebook & Technical Review - 2024 - 17

FEATURE ARTICLE
EV Motor Test Solution - View from Above
Using a KUKA robot, the UUT is brought to the final performance
testbench to ensure accurate alignment within the component.
It must maintain its horizontal position, mimicking the position in
which it will be installed within the vehicle.
The assembled subsystem, weighing close to 50 kilos, is placed
in the performance test bench by the KUKA robot. By using 90 kW
of power the system replicates 2 separate scenarios to test the
motor accordingly. The first scenario applies 4750 RPM and generates
166 Nm of torque, followed by decreasing the torque to 56
Nm and replicating 14,000 RPM. By doing this, the station covers
multiple bases for validation of the product housing as well as the
overall assembly. Measurements are verified for sound, vibration
and torque, reducing the risk for any potential damage.
The final performance tester also includes a chiller-based cooling
system to control the high temperatures generated from these test
sequences as well as an industrial-sized battery simulator.
The battery simulator is essential for this setup, offering many
benefits to the product and the user. Acting as a simulator, it also
recuperates any over expenditures of energy and reuses it to
power the test bench itself. By having the battery simulator, it renders
the solution extremely energy efficient, saving the client from
high costs and waste. It is also one of the key failsafe features
within the test solution in the event the system must be powered
off quickly.
Once testing is complete, the motor is returned to the production
line, and sent to the laser marking station. Here all designated
information such as serial number is characterized within the
components and the EV motor is ready for market.
The entire system is managed by a combination of PLC controllers
and an external PC. The controllers manage the signal handshaking
throughout the automated line while the PC commands
each UUT to execute the desired speed and torque requirements.
The measurements need to be highly accurate and are communicated
quickly via Unified Diagnostic Services (UDS). Test results
are stored within the internal database, sorted by serial number.
What was once a manual process including communication of all
results one serial number at a time, has been completely replaced
and fully automated. Operator intervention has been eliminated,
test results are more accurate and test time was reduced from 45
minutes to 5 minutes per unit.
As a global Test & Quality Solution leader, Averna partners with
product designers, developers and OEMs to help them achieve
higher product quality and accelerate time to market. Founded
in 1999, Averna offers specialized expertise and innovative test,
vision inspection, precision assembly and automated solutions
that deliver substantial technical, financial and market benefits for
clients in the automotive and EV, life-science, battery, consumer
electronics, industrial, telecom, transportation, and aerospace and
defense industries.
For more info, see www.averna.com.
2024 * e-Power Technology 17
http://www.averna.com
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