Advanced End-of-Line Testing to Enhance EV Motor Performance and Operational Uptime

Use case: -End-of-Line (EOL) EV motor testing solution for two- and three-wheeler motors, ensuring accurate torque measurement, system reliability, safety compliance, and high-uptime 24×7 operations.

Goal: -To improve test accuracy, system uptime, and safety while supporting continuous production and reducing motor rejections, warranty risks, and operational disruptions.

Challenges:-Torque instability, software freezes, and controller–dyno communication issues affected test reliability, while high current backflow, electrical failures, noise compliance, and nonstop operations increased production risk.

Solution:-iASYS stabilized the test bench by recalibrating torque sensors, optimizing inverter tuning and algorithms, improving electrical safety, and implementing controlled automation for continuous, compliant operations.

Results :-Reduced motor rejection rates by up to 40%, decreased unplanned shutdowns by up to 70%, increased first-time acceptance by up to 35%, and delivered a scalable, high-uptime EOL testing system with predictive insights.