AVL Focus - Issue 2024

Highly Efficient

E-Axle Testing

The e-axle combines electrical, electronic, and mechanical

systems in a subsystem – which increases testing requirements.

AVL is familiar with these requirements and provides a highly

efficient complete solution.

odern e-axles are at the core of the propulsion system

Jor electric and electrified veLicles. 8Ley comFine tLe

electric motor, inverter and transmission in a highly

integrated subsystem. This enables e-axles to be integrated

easily in vehicles. However, as a subsystem, they must

safeguard all relevant load situations for individual components.

What does this mean for the test system? The testbed must

enable simple installation of e-axles but does not have to be

designed witL tLe same degree oJ ƽe\iFility as conventional

propulsion systems. There is no need for complex UUT

mounting systems like needed for conventional propulsion

configYration and transmission tyTes, or Jor a Fase Tlate witL

cushioned foundations. With the AVL E-Axle TS™, the two load

units are mounted on a common frame. This is decoupled

from the building with polymer elements, making it suitable

Jor installation on any indYstrial ƽooring. -t is also mYcL more

compact than conventional propulsion system testbeds.

The use of a climate chamber and the corresponding

conditioning systems enables testing at various ambient

temperatures, as required by the testing standards for e-motors

and inverters.

DC units are used for electric supply or load, applying models

to configYre FoYndary conditions tLat mimic realistic driving

situations (with a battery model, for example).

*ocYsing on eƾcient testing tLat continYes to deliver reliaFle

results, the AVL PUMA 2™ automation system and the integrated

AVL EMCON 6™ control Lave Feen e\tended sTecifically Jor

e-axle testbeds. Thus, the high-performance software enables

systematic testing of all components for the e-axle. Speed and

torque are determined and regulated precisely, using a specially

developed regulation procedure. Operation involves specifying

a speed for the load systems and a torque for the e-axle, or in a

vehicle simulation that mimics real operation. For a single-motor

e-axle, the system also controls the speed and torque difference

for the differential. In the case of a twin motor e-axle with two

independent e-motors, both motors and the load system are

controlled independently. In conjunction with clear parameter

FlocOs and oTerating windows, tLese control configYrations Jorm

part of our comprehensive automation solution, allowing AVL

to test ea\le testFeds e\tremely eƾciently in terms oJ time and

costs.

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