However, there is no doubt that a neutral testing body helps assess risks more accurately and avoid unexpected costs in electric motor projects.
The “10x Rule of Error Costs” in quality management states that the cost of error prevention or correction increases by a factor of ten at each stage of the value chain. For electric motors, this means: if a defect is only discovered during the prototype phase instead of during planning, the cost of rectifying it increases tenfold.
The 10x Rule in Practice for Electric Motors
If an error in an electric motor system is detected during production, the cost of correction already multiplies by one hundred. If the defect is only discovered after market launch, the cost rises by a factor of one thousand. In light of these enormous cost increases, it’s no surprise that late-detected errors in electric motors can ruin entire companies.
A real-world example illustrates this well: a company developing a dialysis device with special electric motors had to start over after a defect was found during the prototype phase. An even more severe case involved another manufacturer whose digital stethoscope with integrated electric motors showed a critical defect only during the pre-production phase.
Development-Accompanying Tests for Electric Motors
The solution lies in early-stage, development-accompanying testing of electric motors. Instead of checking requirements only at the end of development, critical aspects should be continuously validated – especially in electric motor systems where mechanics, electronics and software are closely interlinked.
External lab service providers offer the advantage of neutrality. They are not involved in the development process and can objectively evaluate whether the selected solutions for the electric motors work as intended. In addition, specialised labs have the testing equipment and expertise that many companies lack internally.
Critical Phases in Electric Motor Development
Particularly sensitive in electric motor development are the transitions between phases. The move from concept to functional prototype is a critical stage where theoretical designs meet practical reality. Many issues invisible on paper become apparent only in the first prototype.
The next crucial stage is the transition from prototype to pre-series production. Here, manufacturing factors come into play – tolerances, material variations and production methods can alter the behaviour of electric motors and cause deviations from the intended design.
Cost Optimisation Through Early Validation
Investing in early testing for electric motors usually pays off after avoiding just one redesign. Lab testing costs are minimal compared to a complete redevelopment or even a product recall.
Especially valuable are tests that address critical functions and edge cases. Thermal tests simulate extreme temperatures; EMC tests reveal electromagnetic issues; lifetime testing provides insights into long-term stability.
Choosing the Right Lab Partner
Selecting the right laboratory for testing electric motors is essential. The lab partner should have application-specific expertise. For example, a lab specialised in medical technology understands the particular requirements of electric motors in this field better than a general-purpose lab.
Availability of required test equipment is another key factor. Not every lab can perform all necessary tests. Early alignment on testing scope and lab capacity prevents delays in the project timeline.
Documentation and Traceability
All development-accompanying tests for electric motors must be carefully documented. Test results form the basis for design decisions and must be traceable. In regulated sectors such as medical technology, thorough documentation is even mandatory.
Documentation should include not only results, but also testing conditions and methods used. Only then can the findings be correctly interpreted and reproduced if needed.
ROI of Testing in Electric Motor Projects
The return on investment (ROI) for early testing in electric motor development is usually high. Avoiding just one redesign may justify the cost of testing across multiple projects. The ROI is even greater if a product recall or legal consequences are prevented.
Tracking the problems avoided through testing helps quantify the value of quality assurance – something many companies underestimate because the prevented issues are not visible in daily operations.
Conclusion: Investing in Quality for Electric Motors
Development-accompanying tests are an investment in the quality and reliability of electric motors. They help identify risks early and avoid cost shocks. The investment in quality pays off through fewer redesigns, shorter development times and higher customer satisfaction.
Companies that systematically invest in early testing for electric motors not only build better products – they also foster a culture of continuous improvement. This leads to long-term competitive advantages and improved profitability.
Do you want to reduce development risks in your electric motor projects?
Antrimon’s testing experts support you with development-accompanying testing – from the initial idea to series production.You can find out more here:
