Influence of Electric Motor Manufacturing Tolerances on End-of-Line Testing: A Review

Nusrat Rezwana Shahreen Popsi, Animesh Anik, Rajeev Verma, Caniggia Viana, K. Lakshmi Varaha Iyer () and Narayan C. Kar
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Nusrat Rezwana Shahreen Popsi: Department of Electrical and Computer Engineering, University of Windsor, Windsor, ON N9B 3P4, Canada
Animesh Anik: Magna International Inc., Aurora, ON L4G 7L6, Canada
Rajeev Verma: Data Simulation and IoT, Corporate Engineering and R&D, Magna Services of America, Inc., Troy, MI 48098, USA
Caniggia Viana: Department of Electrical and Computer Engineering, University of Windsor, Windsor, ON N9B 3P4, Canada
K. Lakshmi Varaha Iyer: Advanced Powertrain-Chassis Americas, Corporate Engineering and R&D, Magna International Inc., Troy, MI 48098, USA
Narayan C. Kar: Department of Electrical and Computer Engineering, University of Windsor, Windsor, ON N9B 3P4, Canada

Energies, 2024, vol. 17, issue 8, 1-12

Abstract: Electric vehicles (EVs) are propelled by electric traction drive systems (ETDSs), which consist of various components including an electric motor, power electronic converter, and gear box. During manufacturing, end-of-line testing is the ultimate step for ensuring the quality and performance of electric motors in electric vehicle (EV) traction drive systems (ETDSs). The outcome of end-of-line testing of electric motors is significantly influenced by the tolerances of their structural parameters, such as stator inner and outer diameters, magnet dimensions, air gaps, and other geometric parameters. The existing literature provides insights into parametric sensitivity, offering guidance for enhancing the reliability of end-of-line testing. In this manuscript, the importance of end-of-line testing and the role of manufacturing tolerances of e-motor structural parameters in the manufacturing process of ETDSs are discussed. The impact of tolerances of e-motor structural parameters on the test results, such as torque, efficiency, back EMF, and e-NV (noise and vibration), is investigated. Finally, key challenges and research gaps in this area are identified, and recommendations for future research to mitigate the drawbacks of end-of-line testing are provided.

Keywords: electric motor; electric vehicle; end-of-line testing; manufacturing; parametric sensitivity; structural parameters; tolerance (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2024
References: View references in EconPapers View complete reference list from CitEc
Citations: View citations in EconPapers (1)

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