Electric motor test time cut

As electrification expands beyond passenger vehicles into sectors including aerospace, off-highway, defence and marine, engineering teams are under increasing pressure to shorten development timelines while maintaining strict performance and safety validation.

Building on decades of automotive electrification experience, DSD has developed an automated test programme that addresses one of the most time-consuming stages of electric powertrain development: motor optimisation mapping, which traditionally requires extensive engineer supervision and long periods of dyno testing.

Using a proprietary MATLAB/Simulink-based automation routine, the system performs rapid four-quadrant Max Torque Per Amp (MTPA) optimisation loops and can run approximately 20,000 test points in under 48 hours. Designed for continuous unmanned operation, the platform automatically manages thermal conditions and maximises test facility utilisation while producing highly repeatable datasets for model correlation and digital twin development.

In customer programmes, the approach has reduced optimisation testing time by more than 75% compared with typical OEM best-practice processes, allowing engineering teams to complete more development iterations within shorter programme windows.

Alongside automation, DSD is also introducing advanced fixture and rig techniques that enable real-world load conditions to be replicated earlier in development. By applying representative wheel or propeller loads to motors and gearboxes during rig testing, engineers can validate mechanical behaviour and durability before vehicle or aircraft integration.

This capability is proving particularly valuable for emerging aerospace electrification projects, where early validation can reduce programme risk and avoid costly flight-test iterations.

Rob Smith, head of development and test at Drive System Design, said: “Many sectors are now entering the same electrification journey that automotive has already undergone, but with even higher expectations around traceability, safety and validation discipline. By combining high-performance test rigs, automation and repeatable engineering methods, we’re helping customers generate the data and confidence they need earlier in the programme.”

www.drivesystemdesign.com