With this assembly and test room for truck e-axles for a German OEM, JW Froehlich is adopting responsibility for the entire facility, which includes electrical tests, leak tests and the end-of-line (EOL) test stand, as well as assembly operations, oil filling and transport systems, and the final preparation for dispatch. Special components – such as load lifting equipment, control cabinet platforms and crane or screw systems – are purchased and implemented in the test room. The complete system is then delivered ready to use.

Once the e-axles under scrutiny have been delivered by forklift truck, the test parts, weighing approx. 1,100 kg is loaded onto the testing line’s automatic conveyor system with a crane system. The walk-in conveyor system is designed to handle a total weight of 2,000 kg. Leak testing for the complete product range is initiated once manual cable pre-assembly and assembly at ergonomically designed stands is complete. Next, the gearboxes and the e-engine compartments are filled with oil and the covers and the various adapters are fitted. The subsequent automatic test run is divided into three stations: initial HV test, functional tests on the EOL test stand, and the second HV test. The assembly and testing process is completed with the inspection of the e-axles on the reworking stand and – provided the permissible limits are not exceeded – with the final preparation for dispatch (including quality control, attachment of the type plate and masking).

The test room was tailored to the client’s needs after close coordination with them. Aside from the seven-minute cycle time, the client specified that the truck rear axle, which was powered by batteries or fuel cell aggregate, needed to meet both EU and NAFTA market requirements, and that the test scope had to meet the requirements of both trade zones. The company uses these e-axles in all their large heavy goods vehicles.

Assembly procedure and test method

Assembly and test process

• delivery and loading
• preassembly and assembly (cables)
• leak tests
• filling with oil (with preparation and temperature control)
• first HV test (automatic)
• adapter assembly
• EOL test/function tests (automatic)
• adapter disassembly
• second HV test (automatic)
• disassembly and media return
• assessment and minor rework
• removal of faulty test parts
• final preparation for dispatch

Test method

• leak testeak testing (all testing spaces)
• HV tests (resistance, LVISO, insulation, voltage resistance)
• functional test of the mechanical and electrical components
• sensor test (temperature, pressure, rotation speed)
• shift actuators function
• cooling/lubrication function
• electric motor function
• structureborne sound test

Final preparation for dispatch

• quality control
• packing, masking
• stamp and attach type plate