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E-Axle Test Bench

E-Axle Test Bench

Electric drives are at the heart of both battery electric vehicles (BEVs) and fuel cell electric vehicles (FCEVs), As manufacturers face growing demands for industrialization and increased production volumes, Our comprehensive solutions support every phase of the project lifecycle—from concept development to implementation and operation. These solutions are designed to cater to a wide range of vehicles, including passenger cars, as well as light and heavy commercial vehicles.

The drive system of an electric vehicle (EV) comprises several key components. Central to this is the e-axle or electric drive unit (EDU), which integrates the electric motor, transmission, and inverter. While we provide dedicated testing solutions for each individual component, it is equally important to test the fully assembled e-axle to identify and address potential assembly-related defects, such as Noise, Vibration, Harshness (NVH) and EMC/EMI testing, which significantly impacts driver and passenger satisfaction and ensure the safety of the vehicle

The system can be 3ways/1 input+2 output, 4 ways, 5 ways, which can be integrated as powertrain testing solution
E-Axle Test Bench​

The comprehensive 3-in-1 electric axle test benches for both light-duty and heavy-duty vehicles address crucial factors such as performance, durability, noise, vibration, and harshness (NVH), as well as electromagnetic compatibility (EMC). These advanced test benches are designed to support manufacturers in developing sustainable electric drive systems that meet the highest standards of performance and quality in the automotive industry. By thoroughly assessing these key areas, manufacturers can ensure their electric axles are reliable, efficient, and capable of delivering optimal performance under real-world conditions.

E-Axle

Light-duty electric axle

We offer a customized solution for the development and validation of light-duty e-axles, whether for single or dual motor configurations. With shortest lead times, manufacturers can quickly begin lifecycle and thermal endurance testing, as well as detailed electrical, mechanical, and thermal property analysis. This advanced test system enables precise performance and functional testing at speeds up to 20,000 rpm and power levels up to 400 kW, supported by a direct drive dynamometer, flexible multi-channel cooling conditioning, and a climatic chamber for comprehensive environmental simulation.

The light-duty electric axle test bench is a customizable solution tailored to the specific needs of manufacturers, whether they are working with single or dual motor configurations. This flexibility enables engineers to develop and validate various units under test (UUTs) efficiently. Equipped with advanced instrumentation and testing capabilities, the test bench allows for comprehensive assessments of the electric axle’s performance characteristics. Its design ensures quick adaptation to different configurations and testing scenarios, making it easier for manufacturers to optimize their electric drive systems for a wide range of applications.

A key advantage of the light-duty electric axle test bench is its rapid delivery time, which allows clients to perform essential in-service lifetime and thermal endurance testing with minimal delay. This expedited timeline is especially critical for manufacturers aiming to bring their products to market quickly while ensuring compliance with rigorous industry standards. The test bench provides valuable insights into mechanical, electrical, and thermal properties, helping engineers identify potential issues early in the development process. By conducting these thorough evaluations, manufacturers can refine their designs, enhance durability, and improve overall performance, ultimately leading to the successful deployment of high-quality electric drive systems in light-duty vehicles.

Heavy-duty electric axle

The Heavy Duty test system is a standardized solution designed for the development and validation of e-axles in commercial vehicles, specifically tailored for trucks and buses. It enables comprehensive lifecycle testing under realistic, vehicle-like conditions. The system supports precise performance and functional testing, with capabilities of up to 20,000 rpm and 400 kW. Equipped with a direct-drive dynamometer, flexible multi-channel cooling conditioning, and a climatic chamber for environmental simulations, it ensures that the e-axles perform optimally across various operating conditions.

The X way-in-1 electric axle test bench is engineered to meet the temperature and service lifespan certification requirements for electric drive units. This system is optimized for efficient testing, allowing seamless integration of duty cycles with pre-configured standardized cycles for temperature aging and lifespan certification during the operation of the Unit Under Test (UUT). This flexibility ensures that manufacturers can thoroughly evaluate the performance and durabilityof their electric drive systems, resulting in more robust and reliable products.

Electric axle test bench for NVH/EMC

The electric axle test bench for NVH is designed to redefine silence, comfort, and overall performance in both light-duty and heavy-duty e-axle solutions. With exceptionally low operating noise levels, it ensures superior NVH performance, making it ideal for the development of quiet and smooth electric powertrains. The system also features semi-automatic track width and wheelbase adjustments, which streamline high-end NVH development, providing engineers with the flexibility to optimize performance easily.

This innovative solution sets new industry standards for NVH engineering in both current and future e-powertrains, ensuring that electric axles deliver not only optimal performance but also maximum user comfort and satisfaction. It is designed to meet the demands of a wide range of mobility applications, enhancing the driving experience and making it more enjoyable for all users.

To measure the electromagnetic compatibility (EMC) of e-drive systems and assess both their emissions and immunity to interference, specialized EMC test systems are essential. We offer precise EMC measurements and testing in accordance with the CISPR 25 standard, ensuring that your systems meet the most stringent industry regulations.

This solution allows for effective evaluation of both the emissions and immunity of your e-axle components, guaranteeing the reliability and compliance of electric drive systems. By using this testing approach, manufacturers can ensure their systems are ready for future mobility applications, offering both performance and regulatory compliance.

Applications of Electric Drive Unit and Electric Axle Test Bench:

  1. Service Lifespan Testing

    • Assessing the durability and longevity of electric drive systems and axles under simulated real-world conditions.

  2. High-Speed and Torque Testing

    • Evaluating performance at both high speeds and high torque levels to ensure optimal functionality under demanding operating conditions.

  3. Torque Differential and Speed Difference Testing

    • Measuring and analyzing variations in torque and speed across the electric axle or drive unit to ensure smooth operation and performance balance.

  4. Peak Power Testing

    • Assessing the system’s ability to handle short bursts of peak power, ensuring the e-drive can deliver maximum output when required.

  5. Electrical to Mechanical Power Efficiency Testing

    • Analyzing the conversion efficiency from electrical to mechanical power, helping to identify areas for improvement in energy use.

  6. Torque Interface to Electric Drive in No-Throttle Test

    • Evaluating torque response and control when the throttle is not engaged, simulating idle or coasting conditions.

  7. xCU Interface to E-Drive for Throttle Test

    • Testing the responsiveness and control of the e-drive when interfaced with the throttle control unit (xCU), simulating real-world acceleration and deceleration.

  8. Driving Cycle Testing

    • Simulating real-world driving conditions by using predefined driving cycles to assess the overall performance and efficiency of the electric drive unit.

  9. Vibration Analysis

    • Analyzing vibrations generated during operation to identify and mitigate issues related to mechanical resonance, efficiency losses, or NVH (Noise, Vibration, and Harshness) concerns.

Thermal Examinations:

  1. Cooling System Stability Test

    • Testing the stability and effectiveness of the cooling system to ensure that the electric drive unit maintains optimal operating temperature.

  2. High-Temperature Operating Endurance (HTOE)

    • Assessing the electric drive’s ability to operate reliably under high-temperature conditions over extended periods.

  3. Powered Thermal Cycle Endurance (PTCE)

    • Evaluating the system’s ability to withstand repeated thermal cycles, simulating various temperature extremes that may occur during operation.

These testing capabilities ensure that electric drive units and axles are thoroughly validated for performance, reliability, and efficiency, preparing them for integration into next-generation mobility solutions.

 

Econo Test is a high-tech enterprise dedicated to provide customers with fast, accurate, and reliable test bench solutions and testing services, covering various fields such as: Automative, Aerospace, Marine, Rail, mechanical engineering, Motorcycles，Pumps，Hydrolic, Turbines and Agriculture machine etc. 

We’re able to do the ODM/OEM and other customization for Parameters/brand/Colour/shape of the bench etc. in order to bring more values and success to our customers!

We provide state-of-the-art testing solutions that support every phase of propulsion development, from initial concept to full-scale production. Our wide range of application solutions integrates various development environments, utilizing the latest methodologies to ensure precision. Our tools are designed to streamline the development process, helping you reduce time-to-market, enhance product quality, and control costs. We lay the groundwork for efficient, future-proof development operations in the era of connected vehicles.

Driven by innovation, we are leaders in our field, meeting the core needs of our customers. We offer cutting-edge measurement and testing technologies for the entire propulsion development process, all built on a unified, integrated, and open platform. Our scalable, high-quality solutions meet the most demanding standards, trusted by even the most competitive racing teams. With a broad array of application solutions, we seamlessly connect virtual and real-world development environments. Whether you need a standalone measuring instrument or a fully integrated test facility, our global team of experts is dedicated to providing support every step of the way.

We are committed to accelerating development, improving flexibility and efficiency, and reducing environmental impact. Our solutions represent the future of testing technology.

Dynamometer
This testing system consists of an operating system cabinet (including an integrated industrial PC, digital electrical parameter measuring instrument, and motor performance analyzer), motor testing software, dynamometer test bench fixtures, and related accessories.
High-Speed Motor Test System
The high speed motor test bench is used to test the motor and UUT in industry as: Automative, aerospace, and Marine etc. The system provides high-speed testing for motors, ensuring optimal performance and reliability.
Electric Drive System EMCEMI
Modern vehicles are equipped with advanced systems like driver assistance, passenger safety features, and both internal and external communication interfaces. However, one of the key challenges lies in controlling electromagnetic emissions and reducing interference between these systems. Ensuring that high-power electric drives operate smoothly alongside sensitive communication systems is crucial for overall performance.
Motor Testing System
Motor test benches are essential for evaluating the performance and functionality of various types of motors. Depending on the testing objectives and application areas, We’re able to cover below categories: For both Asynchronous dynamometer and PM dynamometer (permanent magnet synchronous dynamometer)

Econo Test

Leading the Future of Test Automation with innovative solutions that cater to various industries, ensuring reliability and accuracy in testing processes.

Innovative Solutions

We develop cutting-edge testing systems that address the unique challenges faced by industries such as automotive and aerospace. Our solutions are tailored to enhance efficiency and accuracy in testing.

Customer-Centric Approach

Our commitment to understanding client needs drives us to deliver exceptional support and services. We prioritize customer satisfaction and work closely with clients to achieve their goals.

Visionary Leadership

Led by experienced professionals like Zhejiang University, our team is dedicated to pushing the boundaries of technology and innovation in test automation. We strive to revolutionize the industry.

National high-tech enterprises and certificates


Views of Company：

The company owns modern office/research/production facilities of approximately 10,000m². Our research and technical teams are highly skilled and experienced, enabling us to provide comprehensive technical support, customized services, and solutions to our clients.

Company
Company

We provide comprehensive turnkey solutions for testing facilities, handling everything from initial requirement analysis and design to construction and operational implementation. Our expertise includes seamlessly integrating test systems into infrastructure and managing all necessary utility interfaces. With a forward-thinking approach, we deliver solutions that are built to last, grounded in our deep understanding of development and testing processes. We assist our clients throughout every phase of the project, including consulting, design, procurement, and project execution.

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Get in Touch

We are here to assist you with any inquiries regarding our testing solutions and services.
  • Email: info@econotests.com
  • Phone/WhatsApp: +86 15618770706
  • Address: 3F, Building 2, NO.511 Xiaowan Road, Fengxian District, Shanghai, China

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We aim to respond promptly.

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Let's discuss your needs in person.

   

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