44 Autforce conducts end-to-end testing, including both componentlevel (motors and inverters) and system-level (powertrains and vehicles). Performance and efficiency assessments involve the use of customer-specified measuring equipment and external test devices. If real-time capability is required, the appropriate hardware is integrated to ensure accuracy, according to Jung. For example, Autforce employs the Yokogawa WT 5000 power analyser when necessary, providing a basic power accuracy of +/-0.03% across a broad voltage and current range. Dynamometers are used for simulating real-world load conditions, with test data based on customer-supplied driving tests rather than pre-existing datasets. Thermal and environmental testing capabilities include temperature and climate chambers for extreme conditions. The company also uses image processing with AI capabilities to analyse thermal images. Cooling scenarios for liquid-cooled motor setups are tested using flow temperature, return temperature and volume-flow measurements. For aircooled systems, Autforce collaborates with partner companies to improve measurement accuracy, Jung adds. Thermal runaway testing and thermalmanagement system evaluations are available, with feasibility studies conducted for each project. Durability, NVH and EMI/EMC testing solutions vary, based on project requirements. Equipment is sourced based on accuracy needs, and hydraulic cylinders or shakers are used for simulated roadcondition durability tests. EMI/EMC testing follows regulatory standards, with grounding concepts, EMC shielding and specialised coatings incorporated into test equipment design. Autforce integrates its testing systems with hardware-in-the-loop (HIL) simulation tools for pre-physical testing validation. The company’s data acquisition and analytics capabilities allow for real-time data collection and storage, supporting predictive maintenance and design optimisation. Jung adds that its software has been implemented in multiple industrial applications, building a database that is useful for wear assessment and maintenance planning. The company also integrates automation into its test solutions through its proprietary automation software, Autfactory, which can be configured to meet specific customer needs. It is also parameterisable, meaning the user can change parameters such as measurement values and thresholds during setup. Jung explains Autfactory’s role through its position in a conceptual automation pyramid. At the base of the pyramid is the process level concerned with the machinery, people and processes directly involved in manufacturing. Next comes the field level on which input and output signals are exchanged. Together, these can be thought of as the shop floor. Autfactory is designed to operate on the next three levels up: the control level, where control of machinery through interfaces with programmable logic controllers (PLCs) takes place; the level inhabited by supervisory control and data acquisition (SCADA) systems, and associated human machine interfaces that allow operators to monitor, evaluate and intervene in ongoing processes; and the level where the manufacturing execution system (MES) helps with production planning, production data acquisition, determination of key performance indicators (KPIs), material and quality management. Insight | Motor testing March/April 2025 | E-Mobility Engineering Capable of presenting information in dashboard format, Autfactory software was developed to optimize in-line and end-of-line testing processes and to shorten development cycles for new products (Image courtesy of Autforce) Means the systems can send and receive data in less than 10 ms per cycle. This is crucial in real-time industrial applications
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