EOL test bench for electric motors
PIA Fact Check
- In-house contacting solutions for high voltage, low voltage, and cooling water
- Product inverter simulated using an industrial-grade inverter
- Capability to test multiple variants (high and low types) using a single clamping setup
- Test specimens contacted via a configurable connection box
End-of-Line Testers from PIA – Flexible Test Systems
For many years, electronics have been increasingly integrated into a wide range of products.
End-of-line testing is therefore critical for manufacturers to minimize risks and ensure both user safety and satisfaction. To achieve optimal test coverage with the highest possible throughput, a flexible testing solution from PIA Automation is essential.
PIA Automation recently completed an impressive project involving the development and implementation of an advanced electric drive unit (EDU) test bench. This facility incorporates a range of specialized technologies, including a robotic cell, a setup station to prepare for the test run, an NVH (Noise, Vibration, and Harshness) tester with power electronics and industrial inverter, a blow-out station for cooling water, and a teardown station for packaging the final product.
Flexibility and Innovation: Different Types on One Clamping Setup
A standout feature of this project was the system's ability to accommodate different types of electric drive units on a single clamping setup. This capability was made possible by the development of a versatile connection box and an in-house HV contacting system (6-phase and 3-phase). Active motor cooling, with separate cooling water conditioning, was also integrated into the system.
The system spans approximately 10 x 16 meters and operates with an impressive cycle time of just 67 seconds. It functions both fully automatically and semi-automatically, with the ability to test up to five different types of electric drive units. Another innovative feature is the rotary indexing table in the NVH tester, which minimizes changeover time while maximizing testing efficiency.
PIA delivered several exceptional services for this project, including in-house contacting for high voltage, low voltage, and cooling water, as well as test bench automation via the National Instruments test bench system.
Various PIA Apps and Applications Integrated to Increase Efficiency
The PIA Line Controller was utilized for central process and batch management, allowing for efficient management of process and batch interlocks. Additionally, both order control and recipe management were handled through this software solution, ensuring consistent traceability and optimized material management.
Another key feature was the reworking function of the PIA Line Controller. This function allowed components to be reworked according to their current installation status and then reintroduced into the production line, minimizing material waste and enabling more efficient use of resources.
The piaOptimum and piaAnalyze software solutions—central components of the PIA Industrial App Suite—were also integrated into the system. These solutions were used to evaluate cycle times, analyze individual machining processes, and record message data. With piaAnalyze, correlations within the interconnected system were identified, allowing production parameters to be optimally adjusted, resulting in a reduction of quality losses.
The cycle time statistics feature in piaOptimum proved to be particularly valuable. It enabled targeted comparisons of mechanical modifications, making it possible to quickly assess whether adjustments in mechanical processes resulted in improved efficiency. This feature supported data-driven decision-making and contributed to the ongoing optimization of production processes.
From the Production Line to the EOL Tester – PIA as a Partner for Customized Complete Solutions
Initially, PIA was only considered for the EDU production line. However, PIA didn’t let that limit its potential and presented an innovative and compelling concept. This proposal highlighted the extensive capabilities and customized solutions PIA can offer as a general contractor. In the end, PIA fully convinced the customer and was awarded the contract to supply both the assembly line and the EOL tester. This successful acquisition underscores PIA's commitment and expertise in consistently developing and implementing the best solutions for its customers.
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