Electric test system

for electric motorson siteautomatic

Product description
EOL Pedelec motor function test system for e-bikes with complete programming. Simulations include speedometer, rear and main lights on the motors.

Industry
Electric motors

Challenge
Provide a fully automatic, complete functional test of e-bike motors including communication test and programming. Load simulation must be executed via a frequency‑controlled synchronous motor with very high measurement resolution for torque and speed to detect minimal friction torques in the DUT's planetary gear. The system must be installable in production with minimal footprint in a compact unit (including belt connection).

Solution
Based on test specifications and development documents, a flexible, split concept of test device and mechanical contacting was selected. The system comprises a 19" mobile ESD test cabinet and a mobile adapter with belt connection. The adapter docks to the test cabinet via a modular plug‑in system, allowing the test cabinet to operate with different adapters. Mechanical contacting is fully automatic via integrated control of all actuators in the adapter. For maintenance, actuators can be operated via a touch panel; individual movements and full contacting sequences can be executed. Load machine regulation is implemented as a dynamic PID control loop with a torque measuring shaft.

Benefits

• Highly dynamic motor test system
• Flexible test solution through modular adapter concept
• Complete automatic function test in a single station
• Ergonomic handling thanks to direct belt connection

Technical specifications

• Dynamic load simulation on both pedal outputs, each up to 80 Nm
• Speed range: 0 – 200 rev/min
• Power measurement up to 2 kW
• Torque measurement range: 0 – 100 Nm
• Frequency generator for speedometer simulation
• QR code vision sensor for device identification
• Touch panel for actuator control and maintenance
• CAN communication with DUT programming
• 19" mobile ESD test cabinet with mobile adapter and belt connection
• Modular plug‑in adapter concept to support different adapters
• Fully automatic mechanical contacting controlled by integrated actuator control
• Dynamic PID control of the load machine with torque measuring shaft for high resolution to detect small friction torques in planetary gears
• Compact unit designed for minimal production floor space
• Complete automatic function test including communication test and programming; simulations for speedometer, rear and main lights