Electric motor test system

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Product overview
Test system for 48 V inverters and 3‑phase asynchronous motors (mild‑hybrid applications) with integrated environmental simulation from -20 °C to +70 °C for endurance and functional testing.

Industry
Automotive industry / electric motors

Challenge
Perform realistic static and dynamic tests on mild‑hybrid motor and inverter assemblies. Tests must reproduce operating temperature extremes and allow long‑term endurance analysis that cannot be conducted on production lines due to cycle‑time constraints.

Solution
The compact system combines three separate but integrated stations enabling isolated and combined tests of motor, inverter and the complete unit.

• Motor station: Drives the mounted motor with a 48 V inverter across selectable load points. Measurements include voltage, current up to 500 A, COS‑Phi calculation, power calculation and locked‑rotor test (rotor mechanically blocked to measure short‑circuit current).
• Inverter station: Connects the inverter to a motor simulator and to the cooling circuit. Tests include voltage and current measurement up to 400 A, power verification and CAN‑interface communication validation.
• Complete system station: DUT (inverter + motor) is supplied with 48 V and cooled/heated via the environmental cycle. A load machine coupled to a pulley enables fully automatic test runs. Automatic software discharge at test end ensures personnel safety.

Benefits

• Testing under realistic environmental conditions
• Compact combination of three dedicated test stations
• Fully automatic test sequences after connection
• Low personnel requirement for tests
• Intuitive and easy operation
• Expandable for future DUT variants and additional interfaces
• High flexibility due to generous component design
• Configurable endurance tests for all DUT components
• Ability to test DUTs from different manufacturers on one system

Technical specifications (excerpt)

• Motor current measurement: up to 500 A
• Inverter current measurement: up to 400 A
• Environmental temperature range for endurance tests: -20 °C to +70 °C
• Load machine: adjustable load points, ±120 Nm torque, ±3,000 rpm
• Electronically controlled voltage/current sources: up to ±385 A and 0–60 V
• Measurements: voltage, current, COS‑Phi calculation, power calculation, locked‑rotor test
• Communication interfaces: multiple (including CAN verification)
• Operated components: 48 V inverter and 3‑phase asynchronous motors (mild‑hybrid)
• System layout: three single stations combined for separate and combined testing
• Fully automatic test sequences and automatic discharge for safety