EDS electric drive assembly
With the continuous development of new energy vehicle technology, the integrated design of parts has become an inevitable trend. The most core Electric Drive assembly EDS Electric Drive System part. It mainly includes electronic control, motor and reducer. The highly integrated design not only reduces costs, but also optimizes the overall structure and weight of the electric drive assembly and simplifies subsequent assembly at the vehicle plant.
Single motor/electric control/reducer
2-in-1 (Motor + Reducer/motor + electronic control)
3-in-1 (motor + reducer + electronic control)
At present, many single component suppliers are actively developing and transforming to integrated electric drive assembly suppliers.
Electric machine
The mainstream drive motors are mainly concentrated:
Permanent magnet synchronous motor (e.g. BMW/ BMW i3)
Induction motors (e.g. Tesla/ Tesla)
Switched reluctance motor (Commercial vehicle)
retarder
Based on the characteristics of the motor itself, it is generally necessary to configure a gear reducer with a moderate tooth ratio to meet the power needs of starting and accelerating. (e.g. Tesla/ Tesla 9.73:1 single-tooth ratio reducer)
Electric control
The common electronic control system is an inverter based on IGBT components, which converts the direct current of the battery into the alternating current used by the motor, and realizes the frequency conversion/variable voltage control of the AC motor.
EOL terminal testing, EDS quality assurance
As one of the most important components of electric vehicles, the safety and stability of the electric drive assembly largely determine the quality of the vehicle. At present, advanced manufacturers at home and abroad will use EOL terminal testing for ultimate quality control before rolling off the line, and verify its safety, mechanical structure and electrical properties through a series of tests. At the same time, EOL testing can also find some common problems in the manufacturing process of products, and promote the improvement of the manufacturing process of products.
Kistler electric drive assembly test solutions can be used in customer research and development, testing and production line production. Our test solutions can be customized according to the needs of different customers and different products. Kistler's solution portfolio includes the test of single electric drive assembly components of motors, transmissions and inverters, to the total solution of 2-in-1 electric drive assembly and 3-in-1 electric drive assembly. The test solution can achieve:
Single assembly component testing
2-in-1 or 3-in-1 electric drive assembly test
Automatic operation of the entire test process (for production line inspection applications)
Environmental chamber configurable (for laboratory test applications)
Configurable test content
Performance test condition customization
Test maximum torque support 4280N·m
Customer demand-oriented, provide comprehensive test solutions
Through high-precision sensors, stable mechanical structure and reliable test equipment, Kistler electric drive assembly test solutions can meet all customer test requirements. Among them, the performance test, through the mode of constant speed and changing torque, simulates the performance of various working conditions, and tests the performance of the electric drive assembly online, which can provide complete performance test results, including speed, torque, current, voltage, temperature and efficiency.
The test includes:
Insulation withstand voltage test（Withstand / Insulation）
Equipotential test（potential equalization）
Throw load test （Load Dump-ASC）
Drag force test（Friction Losses）
Active discharge test（Active Discharge）
Harmonic measurement（THD)
Rotary transformer calibration（Resolver offset/Calibration）
Leak test（Leakage test）
Remanence test (Residual Magnetism Test)
running-in（Run-in)
Back electromotive force test （Back-EMF Test）
Noise and vibration measurement（NVH Noise-Vibration-Harshness）
Performance test（Performance Test）
Production line beats, layout covers an area
Depending on the test requirements, the production line beat can be achieved from 120 seconds to 300 seconds
The layout is divided into two categories: inside the final assembly line and outside the final assembly line, the volume and floor area can be designed according to customer needs. The current case 6.5m*6.5m*5.2m 3-in-1, 5m*2m*2.2m single motor.
