EV Driving Module Test Device Simulating Vibration and Dyno Load
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Solution Overview
Problem
Current testing methods for electric vehicle driving modules cannot simulate actual vehicle conditions, leading to unpredicted quality issues and increased design and development costs due to separate performance and durability tests.
Innovation Solution
A driving module testing device that integrates excitation and dyno load tests by using a conveyor system with a pallet to apply vibration and a movable dynamometer unit to simulate real-world driving conditions, allowing simultaneous testing of durability and performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If excitation test and dyno load test are performed separately, then testing process is simple, but actual vehicle conditions cannot be simulated
Solution Approach 1:
The patent combines the excitation test device and dyno load test device into a single integrated testing system. The excitation unit applies vibrations to the driving module while the dynamometer unit simultaneously applies load to the output shaft, enabling both tests to be performed concurrently on the same apparatus, thus accurately simulating actual vehicle conditions where vibration and load occur together
Solution Approach 2:
The testing device is designed with multi-functional capabilities to perform both excitation testing and dyno load testing within a single system. The platform can accommodate different testing configurations and the control system can manage multiple test parameters simultaneously, making the device universally applicable for comprehensive driving module evaluation
2Reliability
If separate testing is used, then device configuration is simple, but development costs increase due to unpredicted quality issues
Solution Approach 1:
By merging multiple testing functions into one integrated system, the patent eliminates the need for separate testing equipment and processes. This consolidation reduces overall manufacturing costs while improving reliability through comprehensive testing that predicts quality issues before production, avoiding costly redesigns and recalls
3Productivity
If separate tests are performed, then testing time is short for each test, but total testing duration increases
Solution Approach 1:
The integrated testing system enables continuous simultaneous operation of multiple test functions. While the excitation unit applies vibrations, the dynamometer unit concurrently applies load and measures output, allowing both tests to proceed without interruption or sequential waiting, thereby maximizing testing efficiency and minimizing total testing time
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables proactive verification of quality problems that may occur during actual vehicle driving, reducing development costs and schedule by simulating mixed driving and vibration environments.
Implementation Method 1
an excitation unit disposed at a position corresponding to the transport path to apply vibration to the driving module by using the pallet
Implementation Method 2
a dynamometer unit installed to be movable in a direction that intersects the transport path to apply a dyno load to an output unit of the driving module
Data Source
AI summary
A driving module testing device for an electric vehicle includes: i) a pallet fixing a driving module for an electric vehicle and transported along a transport path set by a conveyor; ii) an excitation unit installed at a position that corresponds to the transport path to apply vibration to the driving module by using the pallet; and iii) a dynamometer unit movable in a direction that intersects the transport path to apply a dyno load to an output unit of the driving module.