Commissioning, Testing and Validation for Heavy-Duty Machinery
Commissioning and validation of electric and hybrid heavy-duty machinery requires system-level understanding of high-voltage architectures, control software, and real-world duty cycles.
We ensure that electric powertrains, charging systems, and safety functions perform reliably before series production or field deployment.
Why commissioning is critical in heavy-duty electrification
Electrifying mobile machinery and heavy-duty vehicles increases system complexity. High-voltage components, software logic, and mechanical interfaces must work together under load, in varying environments, and often in demanding field conditions.
Commissioning and testing are a crucial phases, where the electrical safety and operational functionality of the powertrain are confirmed before machines are put into service. Our structured and self-contained process ensures smooth execution without the need for external stakeholders.
Poorly executed commissioning often leads to,
delayed production start
repeated field troubleshooting
unexpected charging or communication issues
safety-related uncertainties
costly redesign loops
High-Voltage and Safety System Validation
Electrical safety can be ensured with a series of inspections and measurements of the high voltage system. These include validating the ground continuity of the powertrain component enclosures and machine chassis, and insulation resistance between the high voltage system and machine chassis.
Functional safety is achieved by well-designed safety-related control systems that detect risks and respond appropriately by example; limiting speed, stopping the motion and in the end handles transition to a safe state of the machine
Key safety functions include:
Emergency stopping, safe braking/safe motion, steering control, overload protection, and operator presence detection.
Systematic Testing of Electric Powertrain Functionality
After safe operation is ensured, we verify that all the electric powertrain components are correctly parametrized and operating accordingly. The logic level operation, such as communication between the components and I/O controls, are all systematically tested. The thermal management components and coolant lines are typically filled and bled at this point.
How safety creates confidence in daily operation:
- by preventing hazardous situations caused by system failures
- by reducing risks from human error and environmental factors
- or from a combination of these
Ensuring Safe Electrification Through Best Practices
We take the safety of our customers, operators and our teammates very seriously at Hevtec. We support our customers with the level of help that they need by providing information on best practices, hands-on assistance and instructing personnel how to operate and maintain the electric powertrain.