Electric Motor Testing

What Is Electric Motor Testing?

E-motors are at the core of electromobility and, alongside batteries, are the most critical components that determine the performance and autonomy of new energy vehicles. E-motors must be coupled with an inverter to form an Electric Drives Unit (EDU).

These units can then be integrated into a larger system, the e-Axle, combining the electric motor, the power electronics, and the transmission, to provide a compact and efficient solution to power electric and hybrid vehicles.   

Why is Electric Motor Testing Necessary?

As a critical component of the vehicle, the e-motor must be tested to ensure its safety and reliability in usual and harsh conditions (climatic, vibrations and electric loads) and its effect in vehicle electronic system as a whole (EMC). Applus+ Laboratories is a specialist provider of e-Motors testing services.

How Does EMC Testing on E-Motors Work?

The electromagnetic compatibility of the EV motor with the rest of the electronic systems is a key component of the vehicle’s electric architecture. E-motors can be tested under various configurations each one simulating different operation conditions:  

• EDU in static configuration: idle / rotor locked 
• EDU under dynamic configurations: 
  • Driving mode 
  • Regeneration or braking mode 

All our EMC labs are equipped to test e-motors in static and back-to-back configurations, with dedicated high-voltage power supplies, cooling systems, as well as communications tools available (INCA, Vector CANoe, and LabView).

EMC testing of E-Motors in Motion

In order to test the electric motor, EDU or e-Axle, in motion (driving mode), a special dynamometer is required to simulate realistic operation conditions of speed and torque.

We have different solutions for testing electric drives in motion at our laboratories in Europe and China.  

• Mobile Dyno: Located in our UK lab in Silverstone, this portable test bench of 140 kW can be set up on the turntable of our 10m measurement semi-anechoic chamber.  While the e-motor and the EMC-silent dyno spin, we can take EMC measurements at 360 degrees. The dyno was developed in-house by our engineering team.  
• Fixed Dyno: Located in our Shanghai Lab, a fixed dyno of 220 kW placed outside the semi-anechoic chamber, connects through a shaft with the e-motor.   

Both systems are bi-directional, which allows it to simulate different driving mode configurations, including road simulation and regenerative braking mode.

Environmental, Vibration and Electric Testing on E-Motors

E-Motors and EDUs are exposed to different conditions during their service life that can affect their performance and durability. In our laboratories we are able to simulate vibration loads from shocks, random and sinusoidal vibrations, combined with harsh environmental conditions and electrical loads.

Between the tests, extensive parameter tests consisting of leakage tests, electrical tests, NDT and detailed evaluation of all relevant CAN protocols are carried out.

Why Choose Applus+ Laboratories for Electric Motor Testing

Choosing Applus+ Laboratories for your e-motor testing means partnering with a leader in automotive testing solutions. Our comprehensive range of testing capabilities, combined with our commitment to client service, makes us the ideal partner for all your e-motor testing needs.

Applus+ Laboratories aims to be a one-stop shop for e-motor testing, offering a full range of services to support your product development and accelerate your time to market. We offer:

• Advanced test bench solutions for real-world motor simulation
• Environmental and vibration testing for complete durability assessments
• Product qualification and performance testing

With a presence in key locations worldwide, we deliver our testing services globally, ensuring you have access to the best in e-motor testing no matter where your project is based.