Endurance testing in back-to-back configuration: We have 15 test benches to evaluate the endurance of your electric motors or your electric traction units by means of durability cycles with a wide range of temperatures with independent control for ambient and for coolant, powerful battery simulators and humidity control.
Endurance tests with customer-customized profiles
24 / 7 / 365 automatized operation
Very fast failure reporting as if we were next door to you
Worldwide OEM standards, i.e. LV124, including parameter tests
Damage pre-detection system based on vibration analysis
Component testing: We also have 3 climatic chambers equipped with DC and AC power supplies to evaluate any kind of HV component:
e-motor rotors & stators
Power electronics: DC/DC converters, OBCs, home chargers …
HV ancillaries: PTC heaters, heat pumps …
Performance and characterization testing: Through a comprehensive programme of electrical, mechanical and thermal testing we can perform full validation services. At IDIADA, we validate your electric motors or electric drive traction units assuring they are fit to be marketed through tests adapted to various worldwide standards and regulations.
Dielectric strength, isolation resistance, equipotential bonding and quiescent current tests
Back electromagnetic force, locked rotor, park lock actuation tests
Cooling circuit leak and pressure drop tests
Full design validation plan generation and execution (DVP): We generate a full design validation plan (DVP) for the electric traction unit as a system and for each of its subsystems (e-motor, inverter & transmission) based on product philosophy and specifications, market and user requirements and legal and certification requirements.
Simulation, test and homologation plan
Prototype list and configuration
DVP execution in our facilities
Other electric motor tests:
Vibration tests under climatic conditions
Environmental: Water, Dust, Damp heat
Mechanical shocks, thermal shocks…
IDIADA is well-equipped with cutting-edge facilities designed to perform various types of tests of electric motors and traction units:
Climatic chambers from -40ºC up to 120ºC. with 1.400 x 1.400 x 1.000mm dimensions and up to 1.000 kg. Possibility for humidity control in some benches
Coolant conditioner of 25kW @ -20ºC cooling power with independent flow and temperature control
Battery simulators up to 400kW / 1000V / 1400A
Damage pre-detection systems
High precision sensor for all the mechanical, electrical and thermal parameters
State-of-the-art CAN communication and control equipment
Electric motor engineering services:
The electric motor or traction unit engineering services, combined with our complementary services in the electric (EV) and hybrid (HEV, PHEV) vehicle field, place IDIADA in a leading position to support your component or systems development, from concept to full vehicle validation.
IDIADA unifies multidisciplinary virtual development working groups in areas such as: Electronics, electrical, mechanical, rigid body and NVH.
1D Electronic drive unit simulation for obtaining current patterns (AMESIM & SIMULINK)
1D & 3D Thermal simulation for the evaluation of the heat distribution over the machine (STARCCM+)
3D Structural simulation to determine the forces applied to the motor (SIMCENTER 3D)
3D Electromagnetic simulation to calculate the flux and the torque response (PLM MAGNET)
NVH analysis for the determination of the acoustical response of the machine (SIMCENTER 3D)
Main simulation activities:
Troubleshooting: Electric motors can be replicated into a magnetic model in order to emulate its electromagnetic behaviour. This model can help to identify possible flaws of design, such as hot spots, flux leakages, electromagnetic forces imbalances, etc.
Optimization: Parallelly, the electromagnetic model can be used for design optimization, modifying its own parameters to produce improved performance. This can be achieved by increasing airgap magnetic flux density, reduction of Eddy current losses, end ring copper losses reduction, etc.
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