End-of-line tests, calibration, series release and production statistics at the push of a button.
Rotor position sensors: a key component of electric drives
Rotor position sensors, also known as resolvers, rotary encoders or simply encoders, are the "eyes" of the electric motor. They capture the exact angular position and speed of the rotor in real time and feed this information to the motor controller. Even the smallest deviation shifts the magnetic fields, costs efficiency and, in the worst case, forces the drive into limp mode.
Modern electric vehicles switch to sensorless control if the sensor fails, but that mode works only to a limited extent and at low speeds. Reliable sensors remain indispensable.
The principle: a rotor (target) turns in front of or inside a stator, separated by an air gap. Manufacturing tolerances create typical fault patterns, which we reproduce deliberately on the test stand:
- Eccentricity of the rotor (target)
- Tilt of the rotor (target), also called wobble
- Offset of the target relative to the sensor in X, Y and Z (deviation from center)
- Tilt about X and Y or rotation of the sensor (stator) relative to the rotor (pitch, yaw, roll)
Add extreme operating conditions, from -40 °C to +180 °C and speeds up to 30,000 rpm, and only specialized test stands can reproduce these scenarios reliably and repeatably.
Typical applications of rotor position sensor test stands
Our test stands for rotor position sensors are used across industries and departments, from sensor manufacturing to vehicle end-of-line testing. The focus is on these applications and test tasks:
Sensor manufacturers
E-motor development
Checking signal quality at up to 30,000 rpm to optimize air gap and target concepts.
Automotive OEMs
Verifying supplier specifications, running sample and endurance tests.
Quality labs
Investigating failure causes, compiling service life statistics and standard test reports.
Electronics manufacturing
Simulating temperature cycles and burn-in, catching early failures before shipment.
THE SOLUTION
TMX test concepts for rotor position sensors
We develop modular, scalable test solutions for the analysis, qualification and endurance testing of rotor position sensors. Our systems combine mechanical stability with high-resolution measurement technology, freely configurable drive profiles and intuitive operation. In series production or development validation, TMX gives you exactly the test station you need.
Modular building block system
One solid base, many options: with our modular system you choose only the modules your current test task needs, and add more when requirements change. Your rotor position sensor test stand stays flexible, economical and future-proof.
| Level | Module | What you can test with it |
|---|---|---|
| Base | Base motor | Fixed drive without fault pattern adjustment, ideal for pure endurance runs. |
| Option 1 | ThermoShell | Temperature profiles from -40 °C to +180 °C under load. |
| Option 2 | RotorFlex Adapter | Adjustable eccentricity and tilt of the rotor (target). |
| Option 3 | AutoBalance Drive | Automatic balancing of the high-speed motor for vibration-free operation. |
| Option 4 | SensorShift Stage | XYZ positioning system on the stator for offset tests in X, Y and Z (with or without ThermoShell). |
| Option 5 | Goniomaster Add-on | Turntable plus goniometer for tilt and rotation angles of the stator. |
| Option 6 | MultiSensor Test | 1 to 6 devices under test in parallel, with statistics. |
Example configurations for rotor position sensor test stands
The following three test stands show how a base module plus options produces a configuration tailored to your tasks:
YOUR BENEFITS
What makes TMX test stands for rotor position sensors special
In development, in the quality lab or in end-of-line testing, our rotor position sensor test stands deliver transparent results with minimum effort. Every system scales to your needs and, thanks to smart automation, is ready to run in no time. The key advantages at a glance:
Realistic
Original operating conditions from -40 °C to +180 °C and up to 30,000 rpm, fully repeatable.
Scalable
Single or multiple test stations, adapted to quantities and test scope.
High speed
Highly dynamic drives deliver valid measurements even at extreme speeds.
Smart analysis
Automatic triggers, online trend analysis and custom reports deliver decision-ready data in real time.
Simple software
Intuitive interfaces cut training effort and prevent input errors.
Safety
Burst protection, imbalance monitoring and emergency stop protect people and equipment.
YOUR CONTACT
Let's talk
Developing rotor position sensors, or securing quality in production? Talk to us. We'll find the right test solution for your task.
