TRAXIALPowering the EV Future

Long story short

Traxial specializes in yokeless axial flux motors, renowned for their high torque density, efficiency, and reliability, making them a key innovation for EV powertrains. These compact motors are designed for battery-electric and hybrid-electric vehicles, offering benefits such as direct oil-cooling and adaptable drivetrain configurations. To ensure their motors meet strict performance standards, Traxial required a partner capable of providing a sophisticated testing system for precise validation. CTRL Engineering, with its deep expertise in automotive test benches, proved to be the ideal partner for this mission.

“Thanks to its deep understanding of automotive testing 🚗🔧, as well as comprehensive mechatronics knowledge ⚙️, CTRL Engineering is able to provide custom solutions for E-motor ⚡, EDU (Electric Drive Units) 🔋, and powertrain applications 🏎️!”
Alexis Mortagne – Sr. Mechatronics System Engineer at TRAXIAL

Navigating the Challenges of High-Voltage Motor Testing

The development of next-generation motors presents numerous engineering challenges. Traxial’s technology required a testing setup that could handle high dynamic loads, collect precise data, and support real-time control. The hurdles included simulating high dynamic loads for torque and speed variations, acquiring high-speed and high-resolution data from sensors, testing high-voltage systems (ranging from 400V to 800V), automating test sequences, and ensuring safety while operating with voltages as high as 900V.

Customized Test Bench for Traxial’s High-Speed Motors

CTRL Engineering stepped in to provide a highly specialized testing platform designed to meet all of Traxial’s needs. This platform included a combination of electrical design, motor and drive integration, and sophisticated software to handle sensor data acquisition and real-time control. CTRL Engineering’s team built a dynamic test bench capable of simulating various driving conditions and providing the high-level performance insights Traxial required. The system was specifically designed to handle voltages ranging from 400V to 800V, ensuring full compatibility with Traxial’s motors.

The heart of the solution was the real-time control system, which utilized National Instruments PXI hardware for high-speed data processing and automated test management through NI TestStand. The software suite, built using Matlab-Simulink, allowed for precise real-time management of the test bench, simulating various load conditions while monitoring motor performance. The integration of high-performance PARKER motors and high-torque drives was another critical component, ensuring that the test setup could replicate the demanding conditions that Traxial’s motors would experience in real-world applications. This high-dynamic bench design offered the flexibility to test a wide range of motor configurations and conditions, from cold starts to sustained high-performance operation.

Results that propel E-motor innovation

The collaboration between Traxial and CTRL Engineering allowed for precise and repeatable validation of the motor technology, significantly speeding up the development process. Data gathered during testing offered valuable insights into the motor’s performance, thermal behavior, and efficiency under various loads. This data proved essential for refining the design and preparing for mass production. As a result, Traxial’s motors are now closer to offering improved EV range, reduced energy consumption, and lower overall system costs.

Thanks to this streamlined and precise testing process, Traxial has been able to move closer to commercializing its motors, with an emphasis on optimizing the powertrain for mass production. The insights gained from testing are pivotal for ensuring that Traxial’s motors not only meet performance standards but also offer cost-effective and efficient solutions for electric vehicle manufacturers, ultimately contributing to the future of sustainable transportation.

Why it matters to you?

The success of Traxial’s motor development illustrates the importance of comprehensive and precise testing in the field of electric mobility. As electric vehicles become increasingly sophisticated, ensuring that the components, especially the motors, operate safely, efficiently, and reliably is crucial. Rigorous testing helps identify any weaknesses or potential points of failure before the product is brought to market, which is essential for reducing risks and ensuring that the motors perform well in real-world driving conditions.

For companies like Traxial that are pushing the envelope in terms of technological innovation, it’s essential to have access to expert testing solutions. CTRL Engineering’s ability to design custom test benches capable of handling high-voltage systems and complex real-time control ensures that innovative products can undergo the testing they need to succeed in the marketplace. By providing valuable insights, reducing time to market, and supporting safe, effective product validation, CTRL Engineering plays a critical role in helping companies like Traxial bring cutting-edge electric motor technology to the forefront of the automotive industry.