Electric car (Electric vehicle – EV)
Electric car (Electric vehicle – EV)
Design, manufacturing, and installation of an automated EV motor testing system that measures key specifications such as winding resistance, insulation resistance, high-voltage (Hi-pot) testing, no-load test, and load torque. The system also integrates evaluation software with real-time data logging and storage capabilities.
“We are very satisfied with the performance and accuracy of the testing system provided by the IDEA Group team. The solution not only saves inspection time but also enhances traceability and quality control. A professional partner with deep expertise in the automotive industry.”
1. OVERVIEW
The client is FDI with a manufacturing facility in Binh Duong, Vietnam, specializing in the production of electric motors for EVs. They required the development of an automated EV motor testing system to be integrated into their production line. The system needed to perform comprehensive testing of motor specifications at high speed and precision, support full data storage and traceability, and reduce reliance on manual inspection.
Multiple motor models required a flexible clamping mechanism and adaptive control software.
High-precision measurement was needed for resistance, insulation, and load torque.
Testing time had to be optimized to avoid interrupting the production cycle.
Each motor’s test data needed to be stored and traceable via QR code.
Designed a multi-model motor clamping mechanism with automatic position adjustment and pneumatic probe connection.
Integrated specialized measuring devices (torque meter, tachometer, insulation tester, etc.).
Developed a PLC program combined with HMI and PC-based supervision software to control the test process sequentially.
The system automatically scans the motor’s QR code and saves test data under each serial number.
Implemented OK/NG classification with automatic routing to the next station based on the test result
Testing time reduced by 60%, from 5 minutes per motor to just 2 minutes.
Defect detection rate improved by 30% due to comprehensive and accurate testing.
100% of test data is digitally stored, allowing easy traceability and quality analysis by production batch.
The system runs reliably 24/7, meeting industrial production speeds.
Enhanced the manufacturer’s image as a modern, professional factory in the eyes of global OEM partners.
IDEA is one of the leading companies in Vietnam in the fields of design, precision machining, machinery manufacturing and automation solutions. With a team of over 195 talented and experienced engineers working according to high technical standards, IDEA provides innovative and efficient solutions that enhance performance and optimize costs for customers. The group is expanding its market share internationally, affirming its position as a trusted partner of major companies from Japan, the U.S., Canada, and many other countries.
Learn more: www.ideagroupvn.com
