Assembly and test bay for truck e-axles

A one-stop-shop
In this project for a German vehicle ­manufacturer, JW Froehlich implemented a complex assembly and test field for HGV ­e-axles – from design all the way to ­commissioning. What’s more, JW Froehlich managed the entire project, which allowed the efficient integration of all the processes ­required for a state-of-the-art end-of-line (EOL) assembly and test field. 

In the flow 
A crane system picks up the e-axles, which weigh around 1,100 kilograms, and places them on the e-cart of the line’s automatic conveyor system. The cable pre-assembly and electrical cabling are carried out manually. The system then automatically checks the leak tightness of all five testing spaces, fills the gearbox and electric motor compartments with oil and carries out resistance and insulation tests on the first HV test stand. The operators can then attach drive adapters to the e-axles to enable the start of the functional test on the end-of-line test stand. Once the adapters have been manually disassembled, the e-axles undergo a ­second HV test run. If a test part shows ­de­viations, the operators perform a visual ­inspection and rework the part. All test parts that meet the client’s quality standard are labelled, masked and prepared for dispatch at the last station.

Smart use of virtual reality 
The system can test up to 150 axles per day in three-shift operation. JW Froehlich used VR simulation to develop a coherent ­ergonomic concept for the manual work­stations. In the virtual environment, adapter assembly and disassembly could be experienced during the ­planning ­process to improve ­working con­ditions and design the line to ­perfectly accommodate with the 7-minute cycles and eight operators.

Worldwide-compliant test scope
The tested HGV e-axles in our client’s large trucks are powered by battery or fuel cell units and are driven all around the world. This means they must comply with worldwide standards – which has a significant impact on the flexibility of the test field. JW Froehlich routinely met our client’s requirements, namely compliance of the test scope with the standards applicable in different trade zones.

Implementation as planned 
JW Froehlich was responsible for the complete design of the ­assembly processes, test scope, synchronisation between the stations, ­simulations, data communication and commissioning for the project. The system includes all loading and ­unloading units, manual and ­automatic test stations including the platforms, as well as the ­necessary equipment and logistics. Under JW Froehlich’s project management, an optimised assembly and test system was created – in a one-stop-shop. The time from the start of the project to the start of production was 14 months as terminated.