Advanced EOL test for EV component end-of-line quality

The end-of-line EOL test equipment and automatic production line equipment for electric drive units offer a comprehensive solution tailored for the rapid inspection and performance testing of components used in electric and hybrid vehicles, such as integrated electric axles, x-in-1 electric drive units, and 3-in-1 e-axles. Designed to ensure that each unit meets stringent quality and performance standards, the EOL test equipment is equipped with advanced measurement technologies that enable precise assessments of various parameters. This is essential for verifying that components function correctly and efficiently before being deployed in vehicles.

A key feature of the EOL test equipment is its ability to interface seamlessly with the customer’s manufacturing execution system (MES), facilitating real-time data exchange and supporting digital production initiatives. This connectivity enhances operational efficiency by allowing manufacturers to monitor production cycles, track performance metrics, and manage quality control processes effectively.

The measurement accuracy of the EOL test and automatic production line equipment meets specific customer demands while satisfying production cycle times and safety standards. By implementing this sophisticated testing solution, manufacturers can enhance the reliability of their electric drive units, reduce defects, and improve overall customer satisfaction through higher-quality products.

Overview of automatic line equipment composition

The electric axle off-line EOL test and automatic production line equipment adopts modularized design. The structure is simple, easy to use and maintain, and at the same time, interfaces are reserved for equipment expansion and maintenance. In order to meet the needs of mass production of a variety of electric drive axles, the system reserves space for upgrading and transforming into other platforms and quick-change structures.

The EOL test automated production line mainly includes electric drive unit loading and unloading, connector installation, automatic oil filling, current calibration, angle self-learning, product testing, NVH system, automatic oil pumping and blowback, ATE testing, factory self-learning, factory burn-in, fault clearing, automatic laser engraving, manual topography, manual labeling, bracket mounting, manual full inspection, and GP12 and other work stations.

1. Mechanical part of EOL test station

   Modularized design. Each EOL test station has a set of load machine on the left and right (driving the product to simulate the loading state, and conducting performance rotation test on the e-axle. This includes basic operation, constant speed operation, constant torque operation, including but not limited to: low speed, rated torque speed, full-throttle acceleration, deceleration after full-throttle acceleration, and blocked state, etc.). The left and right output shafts are each equipped with a set of torque sensors for testing torque, speed and other signals.

   The EOL test station also contains blocking device, vibration sensor, spindle automatic docking device, product clamping device, overall platform, sound insulation cover, etc.. Through the mutual cooperation and communication of each module, it realizes the product EOL test and performance test.

    

2. Load machine controller

   Adopting high-performance inverter series module to directly control the loading of the load machine, and at the same time, it can drive the load machine to be in the four-quadrant operation modes of forward electric state, feed-back braking state, reverse electric state and reverse braking state during the work. Closed-loop control of the EOL test system according to the torque and speed signals. Containing rectifier, inverter unit, etc., with the function of feeding back to the power grid.

    

3. Bidirectional DC power supply

   It mainly provides bidirectional DC power supply for loader and controller. With high precision and high dynamic response characteristics, it has the function of feeding back energy to the power grid, constant current, constant voltage and constant power output.

    

4. Automation control system

   The automation control system is used for EOL test equipment test automation. The system structure is open for further expansion by the user. It contains automation system hardware platform and automation test software. The system’s temperature, pressure, vibration, current, voltage and other signals are collected in real time through the measurement and control unit.

    

5. Temperature control system

   It is mainly used to provide cooling medium for the load machine and products to maintain a stable test temperature during dynamometry. It has heating and cooling functions, and displays parameters such as control temperature, flow rate and pressure, and transmits signals with the main control system. The industrial chiller provides cooling water (5–30℃) to the left and right loading machine and temperature control, and provides cooling to the product during current calibration.

    

6. Upper computer system

   The upper computer of the bench is based on the test software developed by Csharp or C++ technology, modularized design, with automatic test function and manual test function.

Layout diagram of EOL test equipment test room

The whole process detailed flow of EOL test

EOL test step 1: Product on line

1. The products are transferred to the EOL test cache area and placed neatly, and the operator confirms whether the model number of the loaded products is the same as the production model. If so, the lifting work will be carried out.
2. The operator will use the workshop crane (user-provided) to lift the product to be tested from the material cache area to the line body test pallet stop, and check whether it is fixed.
3. The operator visually sees the product process holes are placed in the pallet pin holes and confirms that the product is parallel to the pallet.
4. After making sure that there is no error, press the confirmation button with both hands to release the product.
5. After the equipment receives the release signal, the RFID reader will erase and clear the information in the RFID card and then release the product to the next station.

EOL test step 2: Quick connect pre-assembly

1. After the lifting is completed on the line, the product runs through the pallet to the quick-connect pre-installation station and stops, and the operator sweeps the code to bind the serial number of the product with the RFID of the pallet.
2. After the equipment binds the product information, automatically lift the pallet. With lifting rotary device, it can realize 180°rotation, which is convenient for manual installation of wiring harnesses and connectors on the back side of the product. The operator manually installs the high and low voltage wiring harnesses, water inlet and outlet quick couplings, and oil pipe quick couplings.
3. After the installation is completed, the operator checks himself and presses the release button. The equipment defaults to the end of the operation and flows to the next station.

EOL test step 3: Automatic oil injection

1. After the product flow stops, RFID reader will get the tray RFID card information. After confirming that there is no error, the equipment automatically jacked up after the floating mechanism to dock the pallet water and oil quick-connect mechanism.
2. According to the information read by the RFID reader, send the oil and oil quantity instruction to the oil filling machine. After receiving the instruction, the oil filling machine starts to fill the oil and feeds back the oil filling quantity to the equipment.
3. After the oil injection is completed, the floating mechanism is automatically disconnected from the pallet water-oil quick connecting mechanism and flows to the next station.

EOL test step 4: Current Inspection

1. After the device completes automatic oil filling, determine which of the two test stations has priority in completing the test, and then the product will be run to the production line that has priority in completing the test. At the same time, open the PC current calibration host computer to communicate with the equipment.
2. Test equipment flow to the current detection station stop, RFID reader to read the tray information. At the same time, the equipment automatically jacked up after the floating mechanism to dock the tray high and low voltage and water fast connection mechanism.
3. After the docking is completed, the device begins to do airtight detection and power on the host computer to send a ready signal.
4. After receiving the request signal, the upper computer starts the current calibration process. After the end of the test, feedback test results to the device.
5. After the test is completed, the device automatically exits docking and flows to the next station.

EOL test step 5: Self-learning

1. Switch on the PC self-learning host computer and equipment communication, while the product flow to the self-learning station to stop.
2. RFID card reader reads the tray RFID card information. After confirmation, the equipment automatically jacks up and then floats the mechanism to dock the pallet high and low pressure quick connect mechanism.
3. After the docking is completed, the equipment starts to power up and sends a ready signal to the host computer.
4. Self-learning host computer receives the request signal to start the self-learning process, after the end of the feedback test results to the device.
5. After the test is completed, the device automatically powers down and exits the docking and flows to the next station.

EOL test step 6: Back-to-back test and NVH test

1. Open the bench operator PC test software and equipment communication at the same time, the product flow to the product test station before stopping. RFID reader to read the tray RFID card information. Through the equipment server and MES system interaction over the station information, and product information is synchronized to send to the test software, the device initiates subsequent actions.
2. The soundproof door is activated to rise, and the test pallet to be tested is transported to the test station and then stops. After the automatic jacking up of the equipment, the two sides of the clamping plate close to the product and gradually clamp the product until the clamping is stabilized.

3. 3. After clamping stabilization, it automatically lifts up and down, and the pallet falls on the bottom limit fixing block. Floating mechanism docking pallet high and low pressure and waterway quick connection mechanism and good air tightness test after the water.
   4. Test half-axis gradually to the reducer into the shaft port to extend, in a slow rotating way to dock the product spline. At the same time, the NVH vibration probe fixed on the robot arm approaches the specified vibration measurement position until it is tightly attached.
   5. Automatically start low-voltage power-up, the system detects the communication status of peripheral devices, etc., and starts high-voltage power-up without any abnormality. The device requests the product to enter the test state and starts testing.
   6. After the test is completed, automatically lower the high pressure, lower the pressure, the system starts blowing water, back spindle. Automatically move to disconnect the water circuit, circuit connection. Roller conveyor rises to top up the test pallet, product clamping device, positioning device loosens the product. Activate the soundproof door to rise, the test equipment is transported to the next station.

EOL test step 7: Pumping and blowing

1. After the test is completed, the product flows to the pumping and blowback station and stops, the RFID reader reads the pallet RFID card information, and the equipment server interacts with the MES system to initiate the subsequent action after the information has passed the station.
2. No matter the product has been tested, the equipment defaults to automatically jack up the floating mechanism to dock the pallet water and oil quick connecting mechanism.
3. After the docking is completed, the equipment automatically starts the pumping and blowing operation.
4. After the pumping and blowing operation is completed, the equipment records the operation time and uploads it to the MES system. At the same time, it automatically exits docking and flows to the next station.

EOL test step 8: ATE test

1. After the product pumping and blowing is completed, the product flows to the ATE test station and stops, the RFID reader reads the tray RFID card information, and the equipment server interacts with the MES system to initiate subsequent actions.
2. After the confirmation of over-station information, the equipment automatically lifts up and sends the product information to the ATE upper computer synchronously waiting for the operator to operate.
3. After the operator confirms the installation of the ATE test harness, he/she operates the button to start the ATE test.
4. ATE host computer receives the start signal to start the test process, after the end of the feedback test results to the device.
5. After the test is completed, the equipment is automatically powered down to exit the docking and released to the next station.

EOL test step 9: Factory burn-in

1. After the equipment ATE test is completed, the product flows to the factory burning station to stop. RFID reader reads the tray RFID card information, through the equipment server and the MES system to interact with the station information and then the equipment initiates subsequent actions.
2. After confirming the information, the equipment will automatically jack up the floating mechanism to dock the pallet high and low voltage quick connecting mechanism.
3. After the docking is completed, the device starts powering up and sends a ready signal to the host computer.
4. The upper computer receives the request signal and starts the factory burning process. At the end of the process, the test results are fed back to the device.
5. After the factory burn-in is completed, the device automatically powers down and exits the docking and releases to the next station.

EOL test step 10: Fault clearance

1. Product flow fault clearing station stops, RFID reader reads the tray RFID card information. Through the equipment server and the MES system to interact with the station information after the equipment to initiate subsequent actions.
2. Confirmation of the station information OK, the equipment automatically jacked up after the floating mechanism to dock the pallet high and low pressure fast connection mechanism.
3. After the docking is completed, the equipment starts to power up and sends a ready signal to the host computer.
4. After receiving the request signal, the fault clearing host computer starts the fault clearing process. After completion, the test results are fed back to the device.
5. After the fault clearing is completed, the device automatically powers down and quits docking and releases to the next station.

EOL test step 11: Fill in the code top printing

1. Product flow fill in the code printing station stop, RFID reader to read the tray RFID card information. Through the equipment server and the MES system interact with the station information after the equipment to initiate subsequent actions.
2. After confirming that the information is OK, the equipment automatically lifts the pallet. The lifting mechanism is equipped with a manual rotation mechanism.
3. After the lifting operation is completed, the operator carries out the marking operation. During the marking process, the operator will find a suitable angle for the operation.
4. After the marking operation is finished, the pallet is restored to a parallel state with the automatic line by the operator’s rotating mechanism. The device detects whether the parallelism is in place.
5. After the operator presses the confirmation button with both hands, the device detects that it is OK, and the device lowers the pallet and releases it to the next station.

EOL test step 12: Coding labeling

1. Product flow coding labeling stop, RFID reader to read the tray RFID card information. Through the equipment server and the MES system interact with the station information after the equipment to initiate subsequent actions.
2. Confirmation of the station information is OK, the equipment will automatically lift the pallet. The lifting mechanism is equipped with a manual rotation mechanism.
3. After the lifting action is completed, the operator performs the labeling operation. During the labeling process, the operator will find a suitable angle for the operation.
4. After the labeling operation is finished, the pallet is returned to the parallel state with the automatic line by the operator’s rotating mechanism. The device detects whether the parallel state is in place or not.

EOL test step 13: Fast connection disassembly and parts installation

1. The product flow of quick connect disassembly and parts installation station stops, RFID reader reads the tray RFID card information. Through the equipment server and the MES system interact with the station information after the equipment to initiate subsequent actions.
2. After confirming that the information is OK, the equipment automatically lifts the pallet. The lifting mechanism is equipped with a manual rotation mechanism.
3. After the lifting operation is completed, the operator dismantles the connectors and installs the parts. During the operation, the operator can find a suitable angle for the work;
4. After disassembling the joints and installing the parts, the pallet will be restored to the parallel state with the automatic line by the rotating mechanism operated by the operator. The device must check whether the parallelism is in place.
5. After the operator presses the confirmation button with both hands and the test is OK, the machine lowers the pallet and releases it to the next station.

EOL test step 14: Appearance full inspection

1. The product flows to the appearance of the full inspection station stop, RFID reader reads the tray RFID card information. Through the equipment server and the MES system interact with the station information after the equipment initiates subsequent actions.
2. After confirming that the passing information is OK, the equipment automatically lifts the pallet. The lifting mechanism is equipped with a manual rotation mechanism.
3. After the lifting action is completed, the operator carries out a full inspection of the appearance. During the operation, the operator can find a suitable angle for the work.
4. After the full inspection, the operator operates the rotating mechanism to restore the pallet to a parallel state with the automatic line. The machine checks whether the parallel state is in place.
5. After the operator presses the confirmation button with both hands, the inspection is OK and the machine lowers the pallet and releases it to the next station.

EOL test step 15: GP12 station

1. The product flows to the GP12 station and stops, and the RFID reader reads the tray RFID card information. Through the equipment server and the MES system to interact with the station information, the equipment initiates the subsequent action.
2. After confirming that the transit information is OK, the equipment automatically lifts the pallet. The lifting mechanism is equipped with a manual rotation mechanism.
3. After the lifting action is completed, the quality control inspector carries out a pre-packing inspection. During the operation, the operator will find a suitable angle for the operation.
4. After the inspection by the quality control operator, the pallet is returned to the parallel state with the automatic line by the operator’s rotating mechanism. The machine detects whether the parallel state is in place or not.
5. After the operator presses the confirmation button with both hands, the test is OK and the machine lowers the pallet and releases it to the next station.

EOL test step 16: Product end-of-line station

1. After the test equipment has gone through the above actions, it flows to the end-of-line station. The operator uses the traveling crane to lift the product from the production line through the hook to the exit area.
2. A single test product to complete the entire testing process.

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