Driving the Next Generation of E-Mobility Solutions

Driving the Next Generation of E-Mobility Solutions Editors Spotlight The global shift toward electrified transportation is reshaping industries and driving demand for more efficient, reliable, and scalable powertrain technologies. As one of the key players in this transformation, tectos is positioned at the cutting edge of e-mobility. The company, founded in 2004 by Dr. Dieter Höfler, has developed over two decades into an innovative and solution-oriented partner for engineering services and test bench components.With a focus on vibration-optimized systems and a strong portfolio of advanced testing technologies, tectos is not just adapting to the future of electric mobility — it’s helping to build it. On their 20th anniversary we take a closer look at tectos’ pioneering contributions to the electrified transport revolution, including its state-of-the-art test beds, innovative eTraction module, and how the company is solving critical challenges in the high-speed world of electric motors. The E-Mobility Challenge: Pushing the Limits of Electric Motors As the industry continues to shift from internal combustion engines (ICE) to electric motors (e-motors), traditional testing infrastructures are struggling to keep pace. E-motors, particularly those designed for high-performance vehicles, can reach rotational speeds as high as 30,000 rpm — far beyond the capacity of conventional ICE testing rigs that max out at around 8,000 rpm. For manufacturers, this disparity presents a critical challenge: How can they develop and test new e-motors without overhauling their entire testbed infrastructure? tectos has answered this question with its eTraction module, an innovative solution that enables manufacturers to upgrade their existing test beds for e-mobility applications. This innovative gearbox module is capable of converting an ICE test rig into a high-speed e-motor test bed or a high-torque powertrain test bed — eliminating the need for costly new dynamometers and inverters. Introducing the eTraction Module: A Smart Gearbox for E-Motor Testing At the heart of this innovation is the tGear gearbox, a sophisticated transmission system designed to handle the extreme speeds and torque levels required for testing high-performance e-motors. The tGear system is modular and compact, offering flexibility in a space-constrained testbed environment. Unlike conventional systems, the tGear gearbox features no axle offset, meaning the input and output shafts are aligned — a critical factor in delivering high-precision testing for electric powertrains. The gearbox can operate in reverse, allowing it to simulate various drive conditions such as high-speed motor output or low-speed wheel rotation, which is key to testing entire powertrain assemblies. Here’s a technical breakdown: As Christoph Hirt, Solutions Engineer at tectos, explains, “The small footprint of tGear is only possible because we worked hard to minimize the amount of oil required within the gearbox. This allowed us to reduce the size of heat exchangers and pumps, delivering a compact but highly effective system.” The eTraction Advantage: Cost-Effective and Efficient Testing The eTraction module offers substantial advantages for manufacturers looking to reduce testing costs and improve time-to-market. By leveraging existing infrastructure, tectos allows companies to conduct high-speed e-motor testing and high-torque powertrain testing on their existing ICE test beds, eliminating the need for an entirely new setup. This versatility offers a cost-effective solution for research and development (R&D) as well as End-of-Line (EOL) testing. Manufacturers can now validate e-motor performance, powertrain durability, and system integration in quicker timeframes, with significant savings in both time and resources. Key Benefits: Expanding Testing Capabilities: tectos’ High-Performance Test Bench Taking innovation a step further, tectos also provides access to one of the most advanced electric motor test benches in the industry. This state-of-the-art facility, available for manufacturers to rent, is designed for e-motors up to 25,000 rpm and 370 kW of power. Equipped with high-precision measurement technologies from Müller-BBM, Dewesoft, Dewetron, HBK, and LEM, the tectos test bench offers unparalleled accuracy in data collection. Combined with an advanced Thermal Management System and a universal inverter, the test bench provides the optimal conditions for testing electric motors under various scenarios. For companies looking to test and optimize electric motors, tectos offers a comprehensive, end-to-end solution. The eTraction module and high-speed test bench provide manufacturers with the tools needed to validate performance at every stage of development—from R&D to EOL testing. Some of the standout features include: Additional Services: Comprehensive Testing and Beyond “tectos offers much more than just cutting-edge testing. The business also provides 3D CAD design and simulation services, which enable producers to virtually test their systems prior to building real prototypes. Christoph went on, “This method guarantees that products are optimised prior to testing and lowers the number of expensive iterations.” Furthermore, tectos provides in-house custom component production, guaranteeing a smooth interface with your testing processes. He said, “tectos guarantees that every facet of the powertrain development process is covered, from initial design to final validation, by offering a full suite of services.” Pioneering the Future of Electric Mobility As the electric vehicle market continues to evolve, tectos remains committed to driving innovation in powertrain testing and optimization. The eTraction module and advanced test benches provide manufacturers with the tools they need to develop the next generation of electric motors and powertrain systems. “We believe that the future of mobility lies in electrification, and our mission is to help manufacturers achieve the highest levels of performance and efficiency,” says Dieter Höfler, CEO of tectos. “By offering cutting-edge solutions and comprehensive testing services, we’re enabling our customers to stay ahead in a rapidly evolving market.” Conclusion: tectos’ Role in the E-Mobility Revolution The road to electrification is a challenging one, but with tectos’ advanced technologies, manufacturers are well-equipped to navigate the complexities of electric powertrain development. From high-speed motor testing to customizable gearboxes and in-house design capabilities, tectos provides a full suite of services designed to optimize performance, reduce energy consumption, and bring cleaner, more efficient transportation to the masses. Whether it’s retrofitting an existing test bed or conducting the most demanding e-motor tests, tectos is driving the future of e-mobility with innovative solutions that power the next generation of electric vehicles. Dr. Dieter Höfler Managing Director Christoph Hirt, Solutions Engineer