Morphology of Testing Technology and Selection Advice for Automotive Process Qualification of Electric Motor Production

Abstract

Electric mobility poses new challenges for electric motors in the traction sector. Until now, electric motors have been used mainly for applications such as actuators, or for fixed operating points such as for industrial or household applications. Driving cycles of vehicles characterized by pronounced dynamics require a robust and high-quality powertrain. This results in an increase in the complexity of the production of the electric motor and thus, adequate quality assurance and testing processes are required in order to be able to manufacture and assemble the products with minimum scrap rate and in a quality that meets automotive requirements in corresponding production level scenarios. The aim of this paper is to present a holistic morphology of essential testing processes along the electric motor production process as well as to develop a planning guide for the selection of necessary testing processes for the design of electric motor production to reach economic production and quality. For this purpose, a morphological box including suitable features and characteristics is defined. Summarizing, the procedure outlined should sharpen the understanding of necessary testing processes for effective quality assurance within electric motor production and subsequently, make the selection of suitable testing processes more efficient in the course of designing an electric motor production system by deriving evaluated selection recommendations from numerous technological alternatives of testing processes.