Custom Electric Transmission Test Equipment Streamlines Production
To support high-volume manufacturing, ACS engineered a custom electric transmission test solution. This advanced tester has become an essential, fully integrated component of the production line, dramatically boosting the client’s overall efficiency.
The Challenge
A major automotive supplier specializing in electric vehicle components was faced with the mandate to implement high-precision End-of-Line (EOL) quality verification for their next-generation electric axle assemblies. As production volumes accelerated, the client required a dedicated, highly accurate electric transmission test solution to ensure every assembly met stringent performance and quality benchmarks before shipment. The core challenge was to design robust electric transmission test equipment that both withstood continuous, high-cycle use with accurate load simulation and safely integrated the manual motor-to-axle assembly into a highly automated, data-preserving sequence. The success of the client’s new electric vehicle platform was directly contingent upon the reliability and repeatability of the electric transmission test process.
The Solution
ACS engineered and delivered a custom-designed EOL transmission tester machine specifically built for production quality verification of the client’s electric axle assemblies. The solution was strategically composed of a stationary controls and power system, which housed the high-capacity electronics, paired with a movable motor-fixture assembly. This innovative, modular approach allowed the movable motor-fixture to be mounted directly onto the electric axle assembly by the operator, bridging the gap between necessary human interaction and automated testing. Once the physical mounting was secured, the automation system, controlled by a robust Allen-Bradley PLC, took over, performing a predefined, safety-interlocked test sequence. For superior data integrity and real-time operational control, an advanced NI™ system was integrated for high-speed data acquisition, control, and recording of all critical test parameters, making this a highly capable piece of electric transmission test equipment.
The Outcome
The deployment of the custom-built transmission tester machine successfully streamlined the client’s EOL process, establishing a reliable bottleneck-free solution for quality verification. The system achieved the client’s goal of production quality verification of the complex electric transmission assemblies, enabling them to confidently scale production. The integrated NI system provided verifiable, high-fidelity data acquisition and recording capabilities, offering critical insight into the performance characteristics of each unit. The combination of the stationary power system and the flexible, movable motor-fixture assembly resulted in a more ergonomic workflow for the necessary human interaction component of the test. This new electric transmission test equipment not only satisfied the immediate production demands but established a long-term, high-performance asset that ensures the highest standard of quality for the client’s electric vehicle components. The electric transmission test process is now fully auditable and repeatable, mitigating risk and accelerating time-to-market.
Key Features
- Production quality verification of electric transmission assemblies through rigorous EOL testing
- Custom transmission tester machine design featuring a stationary controls/power system and a movable motor-fixture assembly
- Allen-Bradley PLC controlling all core functionality related to the test stand operation
- NI system utilized for real-time control, high-speed data acquisition, and seamless integration with existing factory systems
- Automated system execution of the predefined test sequence for consistency
- Design accommodates necessary human interaction to mount the electric transmission axle assembly onto the motor assembly while maintaining safety and data integrity
ACS Services
- Complete turnkey solution
- Comprehensive design, detailed engineering, manufacturing, and assembly
- Controls and Data Acquisition (DAQ) integration
- Implementation of specialized NI data acquisition and integration
- Successful factory acceptance testing and commissioning
