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case study

Design & integration of a test bench for Continental EV powertrain sensors

Challenge: A technological feast

Out of its R&D centre in Toulouse, Continental used to produce different types of sensors for traditional thermal powertrain management. To keep up with the fast-growing electric vehicles market, our client wanted to develop new sensors for Electric powertrains and drivetrains. However, both the rotation speed of electric motors and accuracy requirements are increasing. As a result, Continental Automotive Sensors and Subsystems R&D department needed a new type of test bench to conduct trials and validate the performance of their sensors, with an accuracy of vertical and horizontal position’s measurement of up to 1 μm (or 1/1000) – a huge technological challenge. 

Solution: End-to-end project management

To deliver this ambitious target, Expleo provided end-to-end project delivery. Our services included software development, automation engineering, electrical engineering (both for power and wiring), mechanical engineering, manufacturing & commissioning contract management. Our first-class e-mobility expertise put us in an ideal position to provide state-of-the-art product testing solutions. 

Outcome: A turnkey solution

Expleo oversaw the whole project on behalf of the client, from the design to choosing the bench’s components & suppliers, providing manufacturing management, delivery and integration-commissioning – a real and complete turnkey solution.

Benefits

  • Quality improvement through the production of a high-accuracy test bench 
  • Ongoing skills and knowledge development 

With a constant need to expand the teams’ technical knowledge, this project is one where everyone learns and grows, due to the very high technical requirements needed to reach such a high level of precision. The solutions implemented in the test bench do not exist elsewhere, it is truly pioneering, hence the enthusiasm of our collaborators,

Francis Grihom

Technical Expert, Expleo Group

PRODUCT & PROCESS ENGINEERING

Product design & engineering

As modern products grow ever more complex, our product designers and engineering teams forecast and solve the different challenges undergone by our clients through the product development phase, from preliminary design to materials sourcing.

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