Evolution, Not Revolution: The Dawn of the EV Era is Changing EV Motor Testing

February 24, 2022 - Author: David Suehs - Engineering Manager, Machine Design, Matt Thiel - Director, Integration Engineering

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EV motor testing and electric components

Four Areas of Concern when Modifying Electrification Test Procedures to Accommodate EV Motor Testing

Transitioning to electrified systems requires adjustments to testing procedures throughout the development and assembly processes. During the design phase, testing ensures that products operate as intended and achieve optimal performance. Throughout production, tests are conducted to detect defects and enhance manufacturing efficiency. Quality assurance tests play a crucial role in confirming that finished products meet the manufacturer’s standards.

Although the good old ICE is far from dead, forward-looking manufacturers are making space and investing resources to develop, test, and build electric components including motors and the electric powertrain.

In Assembly Magazine’s article “Evolution, Not Revolution: The Dawn of the EV Era is Changing Motor Testing,” ACS experts David Suehs, Engineering Manager, Machine Design, and Matt Thiel, Director, Integration Engineering discuss the four main areas of concern when modifying electrification test procedures throughout the entirety of the development and assembly chain:

  1. Existing test cells can be adapted to electric needs: In many instances, facilities can transition from testing Internal Combustion Engines (ICEs) to testing electric motors and drive systems without necessitating a complete overhaul. Ultimately, both systems convert energy into motion, requiring measurement and control of parameters such as torque, speed, power, flow, and temperature. Additionally, both systems require mechanisms to absorb mechanical energy and replicate real-world conditions.
  2. Similar, but not the same: While testing electrified systems shares similarities with testing ICEs, it’s not identical. Electric powertrains demand more precise measurement of voltage and current, unlike internal combustion tests where these are less critical.
  3. New systems, new safety concerns: Test cells for electric motors and drives have distinct requirements concerning fluids, temperature, ventilation, and vibration compared to those for ICEs, typically requiring less of these resources. However, electric components introduce new safety hazards such as high voltage, high current, and battery chemistry.
  4. Preparing for an ever-changing future: Futureproofing doesn’t have to feel daunting. It entails detailed planning for space and power, coupled with an awareness of emerging trends. Those who strategically invest in their adaptability will pave the path for innovation.

Read the full article here.

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