<div>Design validation plays a crucial role in the overall cost and time allocation for product development. This is especially evident in high-value manufacturing sectors like commercial vehicle electric drive systems or e-axles, where the expenses related to sample procurement, testing complexity, and diverse requirements are significant.</div> <div>Validation methodologies are continuously evolving to encompass new technologies, yet they must be rigorously evaluated to identify potential efficiencies and enhance the overall value of validation tests. Simulation tools have made substantial advancements and are now widely utilized in the development phase. The integration of simulation-based or simulation-supported validation processes can streamline testing timelines and sample quantities, all the while upholding quality standards and minimizing risks when compared to traditional methods. This study examines various scenarios where the implementation of advanced techniques has led to a reduction in the e-axle design validation plan (DVP), particularly in relation to the start of production (SOP) decision-making quality gates.</div> <div>Many DVPs incorporate tests in a specific order to enhance the validation impact of each sample and to guarantee that preconditioning tests are implemented when necessary. An instance of preconditioning is subjecting a system to thermal cycling. Thermal cycle preconditioning ensures that the sample accurately represents a real-world system when undergoing sealing-related tests, such as ingress protection testing according to ISO 20653 [<span>1</span>]. Assessing the necessary thermal cycling to “bed-in” a sample would be highly elaborate using a physical sample, but it is a straightforward aspect to extract from modern finite element analysis (FEA). A case study will be presented to evaluate the minimum required thermal cycling and determine the cost savings for the DVP.</div> <div>Furthermore, the validation supported by simulations will be showcased in the context of accelerated lifetime testing. Often, accelerating such tests necessitates a balance between the distribution of damages and the overall testing duration. By incorporating safety factors from simulations as an initial input, the distribution of damages can be adjusted to allow for some over-testing on more secure components, thereby reducing the overall testing time.</div> <div>Efficiency assessment will additionally be considered for virtual validation due to the complexity of the measurement and data acquisition, contributing to measurement uncertainty. Furthermore, simulation-based validation will be considered for the case of lubrication testing, which can be hampered by a largely qualitative assessment criteria.</div> <div>Overall, these scenarios will be evaluated for their potential to streamline the overall DVP process in terms of testing time, sample quantity, and critical path duration. This underscores the potential benefits of leveraging advanced DVP techniques for cost and time savings.</div>
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