Mathematical Model for Sizing and Optimizing a Test Bench for Electric Motors of Electric Vehicles

A mathematical model has been formulated to optimize the setup of an end-of-production-line (EOL) test bench that is used to evaluate the efficiency of electric motors or axles designed for electric vehicles. The model can forecast the performance of EOL testing benches and electric motors/axles under a variety of conditions, thereby eliminating the need for extensive physical trials and minimizing the associated energy usage. The proposed model can be adjusted to handle different power ratings of electric motors or axles. The model takes the maximum performance that the electric motors or axles need to guarantee according to the vehicle manufacturer’s specifications as inputs. Subsequently, the necessary performance of each primary EOL test bench component is computed, and the corresponding systems available in the market are chosen based on manufacturers’ catalogues. In this research, an EOL test bench for low-power e-axles (approximately 22 kW) has been designed according to the outputs of the proposed model.