Meeting the Challenges of EV Manufacturing

Building electric vehicles pushes manufacturers beyond the limits of traditional automotive production. High-voltage systems and thermal constraints create an environment where a single misstep can stall ramp-up. To succeed, EV programs need testing strategies that evolve as fast as the technology itself and deliver reliable results under pressure.

Comprehensive EV Testing Services

Our portfolio of electric vehicle testing covers every major system, from the drivetrain to charging equipment. Each solution is designed to minimize risk while accelerating validation and providing the reliable data engineering and production teams need.

EV Motor Test Station by Averna

EV Motor Validation & In-Line Testing

Electric motors are the heart of every EV. We design automated solutions for every EV motor on the production line to validate speed, torque, and resolver accuracy, ensuring every motor consistently performs to specification. With energy recovery and high-speed simulation, manufacturers achieve consistent quality at scale.

Key expertise:

  • High-speed and high-power validation
  • Torque, angle phasing & resolver accuracy
  • End-of-line (EOL) motor testing
  • Energy recovery to reduce operational costs

Advanced Safety & Reliability Testing

Beyond motors and batteries, modern EVs rely on precise electronics and control systems. Averna supports AOI, vibration analysis, ADAS, and ECU validation with advanced test environments that address safety requirements and confirm reliability across the vehicle lifecycle.

Key expertise:

  • Automated Optical Inspection (AOI) and vision systems
  • NVH, vibration, and environmental chambers
  • ECU and ADAS system validation
  • Leak verification and laser marking

Power Electronics & Inverters

Our test benches cover inverters, DC–DC converters, power distribution units, and onboard chargers. These systems undergo rigorous functional and safety testing to meet demanding performance requirements while accelerating manufacturing.

Key expertise:

  • Functional and safety testing
  • Inverters, DC–DC converters, and PDUs
  • Onboard chargers (OBC) and circuit breakers
  • High-voltage and high-current switching

EV Battery Testing & Battery Management

As demand rises, batteries must be proven safe and durable across thousands of cycles. Averna’s modular platforms support testing at every stage, from cells to complete packs. These platforms manage thermal conditions and cycling demands while also validating BMS/TMS operation.

Key expertise:

  • Cell, module, and pack validation
  • Thermal and cycling tests
  • Battery Management System (BMS/TMS) testing
  • Battery sorting and simulation
Exploded View of EV Battery

EVSE & Charging Systems

Charging systems must deliver energy efficiently while protecting both the grid and the vehicle. We provide flexible solutions for testing EVSE hardware, connectors, and onboard charging interfaces, with capabilities that cover high-voltage operation and insulation integrity, as well as leakage detection where required.

Key expertise:

  • EVSE hardware and charging handles
  • Connector and cable validation
  • Insulation and leakage detection
  • Compliance with global charging standards
Car Charging
Parking electric cars. Charging stations

Speak with Our EV and eDyno experts

The power requirements for EV testing are more strenuous and challenging than standard vehicles. Speak to an expert to cover all the extremes.

Averna Electric Vehicle Testing Equipment

 

EVSE - front view

EVSE Test Platform 

Averna’s EVSE Test Platform ensures charging systems meet demanding performance and safety requirements. The solution is built to validate both power delivery and communication protocols, giving manufacturers confidence in every unit shipped. 

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Batterie Inspektor - Front view

Batterie Inspektor™ 

By combining the most diverse hardware and software modules, Batterie Inspektor™ delivers automated battery testing at every stage of manufacturing. With this flexible battery test platform, all modules can be adapted to their respective quality requirements.

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EV Power Components EOL Tester

EV Power Components EOL Platform 

Designed for inverters, DC–DC converters, PDUs, and onboard chargers, this solution delivers reliable end-of-line validation by combining functional performance checks with safety and insulation verification.

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B2P Replication SchemaAccelerating EV Innovation for Industry Leaders

Global OEMs and Tier 1 suppliers trust Averna for our ability to deliver turnkey EV testing solutions in record time. From replicating complete test lines to customizing advanced inspection systems, we help EV leaders build compliance into their processes and maintain an edge as electrification accelerates.

In one recent project, Averna deployed 20 new EV test stations in under six weeks, a benchmark for speed and precision that few can match.

 

They Trusted Us

Discover how Averna’s fully-automated in-line validation solution tackles high-power, high-speed challenges while maximizing energy reuse and minimizing costs. This case study reveals how cutting-edge engineering and smart automation come together to deliver total performance validation directly on the production line. 

Cover - Total Performance In-Line Validation for Electric Vehicle Motors

Learn More About our Electric Vehicle Test Solutions

Webinar_EV_on-demand

Electric Vehicle Test Solutions Challenges - Webinar

Download this 30-minute webinar to learn about the top 3 challenges EV motor manufacturers are facing today and how to address each one.

Cover - Getting Electricity on the Road

A Leading Electric Vehicle Innovator Trusted Us - Case Study

Don't take risks in your supply chain. Find out how Averna got 20 brand new EV test stations up and running in under 6 weeks.

EV Plugged Connected to Charging Station

The Growth of EV and its Challenges

 What changes need to be made to accommodate the latest industry challenges?

Accelerate Automotive Innovation

Talk to our EV test experts today and discover how Averna can help you validate every system and automate your testing process. You will bring high-performance vehicles to market faster!Talk to our experts