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E-Mobility & Automotive
Electric Drive Unit (EDU)

End-of-Line (EOL) Functional Tester

End-of-line (EOL) test bench for the Electric Drive Unit: Performance & Functional Tester
JWF X TeSys Partnership

The requirements of test stand performance for electric drive units (EDU) and their components can vary greatly and strongly depend on the intended application: Development test stands, for example, are highly flexible, but are usually set up manually. Q test stands are used for establishing test parameters for the pre-series and provide a link between development and production. Finally, end-of-line (EOL) test stands have to be particularly efficient, which is why they are often mostly automated. Advice by JW Froehlich on the application-oriented development can help to achieve better cost efficiency, for example by reducing cycle times and limiting the tests to the necessary range of performance and measurements.

JWF + TeSys - E-Mobility & Automotive - Electric Drive Unit - EOL Functional Tester (EDU, PPE)

1

Overview

JW Froehlich’s EOL test stands for functional testing of electric drive units for a German OEM (Audi, Mercedes Benz) have been designed to provide a particularly effective testing process. Transport, clamping and contacting the test parts is fully automated and cycle time optimized, which allows for a throughput of up to 2,000 EDUs per day. To achieve both a maximum of output and the highest possible cost efficiency, comparative measurements are only carried out for the lower operating points. Our in-house test and analysis software thus ensures that the values of both the electrical characteristics and the mechanical components are always within the permissible range.

An additional Q test stand offers OEMs the option of carrying out more extensive and more precise tests under full load prior to the start of series production. The degree of automation is the same as that for EOL test stands, but it is designed for longer test runs, and permanent runs of up to several hours.

2

Highest Precision with Maximum Flexibility & Compatibility

The system is divided into two independent test areas. In the first area, the test object is checked for its basic function, without adapted output shafts, and for its electrical safety. The second test area consists of performance tests, which are all carried out with adapted load machines. Here, the use of a swivel unit and the very rigid, adjustable traversing units for adapting the test objects with the load machines ensures maximum variant diversity. The swivel unit is used to pick up and position the test objects in the prescribed test position. There, high torques can be taken off via driveline. This highly flexible test system enables to test a wide variety of types on a single system.

In addition to mechanical flexibility, the test bench also offers a very broad performance spectrum in terms of electrical capabilities for testing a wide variety of e-Drives.

This means that several e-Drive variants can be tested on one unit with an extremely high power and test voltage and NVH sensing postions are versatile to enhance maximum flexbility.

3

Quality Assurance with in-house measuring technology software (SOLVISO)

The safeguarding of customer-specific requirements for the various eDrive variants is carried out with the aid of JWF's own measurement technology software (SOLVISO), which ensures recording and validation of the measurement signals during the test runs. The increasing requirements for test depth can be better implemented with a customizable test sequence, user interface, data analysis, trend and correlation analysis through JWF's automation software.

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Specifications

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