If a fault in electric motors only becomes apparent during production, the additional costs are already a hundred times higher. By the time the product is launched on the market, the costs are even a thousand times higher. In view of these huge leaps in costs, it is not surprising that faults in electric motors that are recognised too late can plunge entire companies into existential crises.
The rule of 10 for electric motors: Exponentially rising costs
The rule of 10 for failure costs is particularly relevant for electric motors, as they are complex mechatronic systems. A fault in the motor winding that is only discovered during series production can cost millions. The same error that is recognised in the design phase only causes fractional costs.
Practical examples illustrate the scope of the rule of 10 for electric motors. A company developed a dialysis machine with special electric motors. A fault discovered in the motor control system during the prototype phase forced the company back to square one and cost several million euros. The case of a digital stethoscope was even more dramatic: a critical defect in the integrated electric motors only became apparent during the pre-production phase, jeopardising the entire project.
These examples show that tests accompanying the development of electric motors are not only technically sensible, but also economically imperative. The investment in early quality assurance usually pays for itself the first time a redesign is avoided.
Critical test phases in the development of electric motors
There are several critical phases in the development of electric motors in which development-related tests are particularly important. The first critical phase is the transition from the concept to the first functional model. This is where it becomes clear whether the theoretical calculations for electric motors work in practice.
Many problems with electric motors that were not visible in the simulation only become apparent in the first physical prototype. Thermal effects, electromagnetic interference or mechanical resonances can significantly influence the behaviour of electric motors. Early tests uncover these problems before they lead to costly redesigns.
The second critical phase is the transition from functional model to pre-series for electric motors. This is where manufacturing aspects come into play that can influence the behaviour. Tolerances, material variations and manufacturing processes can lead to deviations from the original design. Tests accompanying development in this phase ensure that the electric motors also function under series production conditions.
Test methods for electric motors in development
Development-related tests for electric motors include various methods and procedures. Thermal tests are particularly important as electric motors generate heat and are also sensitive to temperature. Overheating can lead to reduced performance, premature wear or even failure.
EMC tests (electromagnetic compatibility) are essential for electric motors. Modern electric motors with electronic controls can generate electromagnetic interference or be affected by external interference. Early EMC tests avoid costly rework during certification.
Lifetime tests provide information about the long-term stability of electric motors. Accelerated ageing tests can provide insights into the behaviour over many years in a short space of time. Vibration tests check the mechanical robustness, while environmental tests validate the behaviour under different climatic conditions.
External laboratory service providers for electric motor tests
External laboratory service providers offer the advantage of neutrality and expertise when testing electric motors. They are not involved in development and can objectively assess whether the selected solutions work. In addition, specialised laboratories have testing facilities and expertise that most companies do not have.
Choosing the right laboratory partner for electric motor testing is crucial. The partner should have specific expertise in the respective application. A laboratory that specialises in medical technology understands the special requirements of electric motors in this area better than an all-round laboratory.
The availability of the required test equipment for electric motors is also important. Not every laboratory can carry out all tests. Early coordination of the required tests and available capacities avoids delays in the project plan.
Cost optimisation through development-accompanying tests for electric motors
The investment in development-accompanying tests for electric motors usually pays for itself the first time a redesign is avoided. The costs for laboratory tests are minimal compared to the costs of a new development or even a product recall for electric motors.
Tests that cover critical functions and borderline cases for electric motors are particularly valuable. Worst-case scenarios should be systematically tested to validate the robustness of the design. The interactions between different electric motor components must also be taken into account.
Systematic test planning helps to optimise the costs of development-related tests for electric motors. Not all tests need to be carried out in every phase. Risk-based prioritisation concentrates resources on the most critical aspects.
Documentation and traceability for electric motor tests
Development-related tests for electric motors must be carefully documented. The test results form the basis for design decisions and must be traceable. Particularly in regulated industries such as medical technology, complete documentation of tests on electric motors is mandatory.
The documentation should not only contain the test results, but also the test conditions and the test methods used for electric motors. Only in this way can the results be correctly interpreted later and reproduced if necessary.
Systematic archiving of test data makes it possible to quickly access relevant information in the event of later problems with electric motors. Historical test data is also valuable for the further development and optimisation of future generations.
Return on investment in electric motor tests
The return on investment (ROI) of tests accompanying the development of electric motors is usually very high. Even one avoided redesign can amortise the costs of all tests over several projects. The ROI is even higher if this avoids a product recall or legal problems.
Systematically recording the problems avoided by testing electric motors helps to quantify the value of quality assurance. Many companies underestimate the cost of avoided problems because they are not directly visible.
Reputation and customer satisfaction are other important factors in the ROI of electric motor testing. A reliable product leads to follow-up orders and recommendations, while quality problems can cause long-term damage.
Integration into the development process of electric motors
Tests during development must be systematically integrated into the development process of electric motors. They should not be regarded as a downstream activity, but as an integral part of development. This requires close co-operation between development, quality assurance and test laboratories.
Test planning for electric motors should begin as early as the concept phase. Critical aspects and potential risks must be identified and appropriate tests defined. A test plan with milestones and success criteria provides structure and orientation.
Agile development methods can also be used for electric motor tests. Short iteration cycles with rapid feedback make it possible to recognise and resolve problems at an early stage. This is particularly valuable for innovative projects with a high degree of uncertainty.
Future trends in electric motor testing
Digitalisation is also changing the tests that accompany the development of electric motors. Virtual tests and simulations can supplement or partially replace physical tests. Digital twins make it possible to simulate the behaviour of electric motors under different conditions before physical prototypes are built.
Artificial intelligence can help analyse test data for electric motors. Machine learning algorithms can recognise patterns that are not obvious to human analysts. This can lead to new insights into the behaviour of electric motors.
Automated test systems reduce the costs and increase the reproducibility of tests for electric motors. Robots can perform tests around the clock and ensure consistent conditions. This is particularly valuable for long-term tests or tests with many repetitions.
Conclusion: Investing in the quality of electric motors
Tests during development are an investment in the quality and reliability of electric motors. They help to recognise risks at an early stage and avoid super-GAUs. The rule of 10 for failure costs clearly shows that early quality assurance is not only technically sensible, but also economically imperative.
Investing in development-accompanying tests for electric motors pays off in terms of avoided redesigns, shorter development times and higher customer satisfaction. Companies that systematically invest in quality assurance not only develop better products, but also a culture of continuous improvement.
Would you like to minimise development risks in your electric motor projects?
Antrimon's test experts support you with development-accompanying tests from the initial idea to series production and help to nip super-GAUs in the bud. You can find more information here:
