At CONVERGIX, we develop specialized testing and assembly solutions to ensure the reliability of electric vehicles and advanced mobility technologies. Using our experience in EV powertrains, autonomous systems, and energy storage, we create validation and production systems that deliver quality, shorten time-to-market, and fuel transportation innovation.
EV & Advanced Mobility Solutions
Battery, Motor & Powertrain Testing & Assembly
Battery, Motor & Powertrain Testing & Assembly
Challenge
EV Component Validation: Safety & Performance in Evolving Technology
EV manufacturers must innovate rapidly and meet strict standards. Every component—battery cells, inverters, drive units, sensors—needs thorough testing to prevent recalls and ensure safety. Traditional validation lags behind evolving battery chemistries, voltage systems, and driver-assist technologies. Manufacturers must verify critical systems across thousands of scenarios on tight deadlines. Without automated EV testing and assembly, companies risk quality issues, delays, and lost competitiveness.
Solution
Testing & Assembly Systems: Validation & Production for Next-Generation EVs
CONVERGIX delivers specialized testing and assembly solutions for EV powertrains and advanced mobility systems. We validate heat transfer, charging, energy conversion, and sensor performance in real-world scenarios. Our testing centers handle batteries, motors, inverters, and sensors, ensuring all components and full powertrains meet safety standards. Automated assembly and strict testing support rapid, reliable, and safe EV development.
Capabilities
EV & Advanced Mobility Manufacturing Solutions
Battery Module
Automated Battery Module Assembly & Testing Systems
Build reliable battery modules with precision automation that guarantees consistent cell placement, secure connections, and integrated thermal management. Our systems support high-volume production and rigorous quality with automated cell loading, welding, and testing.
Cell Handling & Module Assembly Automation
Deploy specialized systems for safe, precise battery cell processing:
- Automate cell loading with vision-guided positioning for tight tolerances
- Install busbars and interconnects with laser welding or ultrasonic bonding
- Apply thermal interface materials with consistent coverage for heat management
- Integrate compression systems to maintain optimal cell contact pressure
Electrical Testing & Quality Verification
Implement comprehensive validation systems for module performance:
- Conduct electrical continuity and resistance testing on all connections
- Verify voltage balance across cell groups and monitor for anomalies
- Perform insulation resistance testing to ensure electrical safety
- Test thermal management systems for proper heat dissipation
Module Enclosure & Sealing Operations
Automate final assembly processes for environmental protection:
- Apply structural adhesives and sealants for moisture and dust protection
- Install cooling plates and thermal management components
- Integrate battery management system (BMS) sensors and wiring
- Conduct leak testing and final dimensional verification
eAxle
Electric Axle Assembly & Performance Validation Systems
We manufacture integrated eAxle systems with automated assembly, uniting the motor, gearbox, and power electronics into a complete propulsion unit. Our solutions deliver precise gear meshing, correct bearing preload, and verified torque, ensuring high efficiency and low noise for advanced electric drivetrains.
Motor & Gearbox Integration Assembly
Engineer automated systems for precision drivetrain construction:
- Align and install electric motors with micrometer-level accuracy
- Assemble gear sets with controlled backlash and preload
- Install bearings with precise press-fit forces and positioning
- Apply lubricants and sealants for optimal performance and longevity
Power Electronics & Inverter Integration
Implement assembly automation for electrical system integration:
- Mount the inverter and power control modules with thermal management
- Route high-voltage cables and install connectors with proper torque
- Integrate cooling systems for thermal regulation under load
- Install sensors for temperature, speed, and position monitoring
eAxle Performance Testing & Validation
Deploy comprehensive testing systems for drivetrain verification:
- Conduct dynamometer testing for torque, speed, and efficiency curves
- Verify noise, vibration, and harshness (NVH) performance levels
- Test thermal performance under sustained load conditions
- Validate electrical systems and power delivery across operating ranges
Battery Pack
Complete Battery Pack Assembly & Validation Systems
We use automated systems to assemble full-scale battery packs, integrating modules, high-voltage distribution, cooling, and safety features. Our solutions handle large-format complexity, with all connections meeting automotive safety and energy transfer standards.
Module Integration & Structural Assembly
Deploy robotic systems for large-format battery pack construction:
- Position and secure battery modules within pack enclosures
- Install structural reinforcements and crash protection systems
- Integrate high-voltage distribution busbars and service disconnects
- Apply fire suppression materials and thermal barriers
Cooling System & Thermal Management Integration
Implement automated installation of thermal regulation systems:
- Route coolant lines and install thermal management plates
- Connect cooling system components with leak-free fittings
- Apply thermal interface materials between modules and cooling plates
- Integrate temperature sensors throughout the pack structure
Pack-Level Testing & Quality Assurance
Execute comprehensive validation protocols for complete battery systems:
- Conduct high-voltage insulation and isolation testing
- Verify battery management system (BMS) communication and monitoring
- Test cooling system performance and thermal uniformity
- Perform charge/discharge cycle testing to validate capacity and efficiency
- Conduct final leak testing and electrical safety verification
PCU (Power Control Unit)
Power Control Unit Assembly & Functional Testing
We produce advanced power control units by precisely assembling inverters, DC-DC converters, and onboard chargers into compact, efficient modules. Our solutions ensure reliable connections, effective thermal management, electromagnetic compatibility, and verified power conversion and control performance.
Power Electronics Assembly & Integration
Engineer automated systems for complex electronics manufacturing:
- Install inverter modules, capacitors, and power semiconductors with precision
- Apply thermal interface materials and mount heatsinks for thermal management
- Route high-current busbars and install high-voltage connectors
- Integrate gate drivers, control boards, and sensor interfaces
EMI Shielding & Environmental Protection
Implement assembly processes for electromagnetic compatibility:
- Install EMI shielding and grounding components for noise reduction
- Apply conformal coatings for moisture and contamination protection
- Seal enclosures with gaskets for environmental durability
- Integrate cooling fans and liquid cooling interfaces
PCU Functional Testing & Validation
Deploy specialized test systems for power electronics verification:
- Test power conversion efficiency across voltage and current ranges
- Verify inverter switching performance and harmonic distortion
- Conduct thermal performance testing under load conditions
- Validate control signal response and communication protocols
- Perform EMI/EMC testing to ensure electromagnetic compatibility
eMotor
Electric Motor Manufacturing & Performance Testing Systems
We manufacture high-performance electric motors with automated systems for winding, assembly, and validation to meet EV propulsion requirements. Our process includes stator winding, rotor balancing, assembly, and dynamometer testing, ensuring motors provide reliable power, efficiency, and performance up to 20,000 RPM.
Stator Winding & Insulation Systems
Deploy advanced winding automation for consistent motor performance:
- Wind stator coils with precise tension control and layer placement
- Apply insulation materials with automated dispensing systems
- Insert preformed coils with robotic positioning for tight tolerances
- Conduct hipot testing to verify electrical insulation integrity
Rotor Assembly & Balancing Operations
Implement precision assembly processes for rotating components:
- Install magnets or rotor bars with controlled positioning and adhesion
- Balance rotors to minimize vibration at high rotational speeds
- Press-fit shafts and bearings with force monitoring
- Apply protective coatings for corrosion and wear resistance
Motor Assembly & Performance Validation
Integrate comprehensive testing systems for motor verification:
- Assemble stator and rotor with precise air gap control
- Install housing, end bells, and cooling system components
- Conduct back-EMF testing to verify electrical characteristics
- Perform dynamometer testing for torque, speed, and efficiency mapping
- Validate NVH performance and thermal behavior under load
- Test bearing performance and vibration levels across speed ranges
Benefits
What EV & Advanced Mobility Automation Delivers
Accelerate Time-to-Market
Validate designs quickly and scale efficiently from prototype to production through specialized testing and automated assembly.
Ensure Safety & Reliability
Thorough validation simulates real-world use, preventing recalls and ensuring safety in all conditions.
Meet Performance Standards
Rigorous tests confirm efficiency, heat management, power delivery, and sensor accuracy to meet all specs.
Support Rapid Innovation
Adaptable systems accommodate new batteries, voltages, and autonomous tech as the industry evolves.
Maintain Quality at Scale
Automated assembly with integrated controls guarantees consistent, high-volume quality.
Accelerate EV innovation with CONVERGIX's testing and assembly systems.
Assembly
Explore automated assembly systems designed for high-precision, repeatable builds that support sterile, compliant device production.
Robotics
Enhance speed, precision, and flexibility in your operations by integrating advanced robotics purpose-built for complex assembly tasks.
Material Joining
Strengthen your assembly operations with engineered welding, fastening, and dispensing systems that deliver repeatable joint integrity, optimized cycle times, and reliable, cost-efficient performance.
