Testing Records and Corrective Actions
The honest version. This is where we document the problems our own testing turns up — in the lab, on the factory test track, and in extreme trials we pay to run ourselves. Not partnerships that failed: faults we find, trace to a root cause, and fix, with the fix folded back into the standard build before a model ships.
We Go Looking for Failures on Purpose
A problem found on our bench costs us a part. The same problem found on a customer's route costs them a working day — and their trust. So we test hard, in four ways, before a model ships.
Lab Bench Testing
Controlled rigs for the things you can measure: battery cycle life, motor and controller heat, brake force, frame load and fatigue cycles.
Factory Real-World Testing
Loaded vehicles run our factory test track and local roads — grades, broken surfaces, stop-start duty — the way an operator actually drives them.
Extreme & Endurance Trials
Over-load, over-distance and rough-road abuse runs that push past the rated spec to find where the real margin is — not just where the datasheet says it should be.
Self-Funded Field Shipments
We pay to ship test units alongside customers' real cargo to real destinations, so the vehicle is judged by the same handling, climate and route a buyer's would face.
What Broke, Why, and What We Changed
Each record follows the same engineering structure: test type, problem, root cause, corrective action and re-test result. The goal is simple: find weak points before they become customer downtime.
Battery range fell off faster than rated
On an over-distance abuse run, usable range dropped below the rated figure earlier in the pack's life than expected.
A battery-bay layout that let heat build up around the pack on long continuous-duty runs, accelerating capacity loss.
Re-worked the battery bay for airflow and added a heat barrier between the pack and the drivetrain.
Capacity retention held to spec through the full endurance cycle on the re-tested unit.
Controller overheating under sustained load
The motor controller hit its thermal cut-off during a sustained full-load climb cycle on the test rig.
Controller mounting location had poor heat dissipation, and the rated duty cycle was optimistic for hot-climate use.
Relocated the controller to a ventilated position with a larger heat sink, and de-rated the published continuous-duty figure to a value we could hold.
No thermal cut-off across the repeated full-load climb test.
Surface corrosion after a humid-route shipment
A self-funded test unit shipped on a humid coastal route showed early surface corrosion on exposed fasteners and brackets.
Plating spec on a batch of small hardware was below what coastal-climate service needs.
Upgraded the fastener and bracket coating spec, and added a salt-spray check to incoming inspection for those parts.
Clean hardware on the re-shipped unit over the same route; the coating spec is now standard.
Cargo-bed weld fatigue on broken surfaces
Repeated loaded runs over the rough section of the test track produced early cracking at a cargo-bed weld joint.
A stress concentration at the joint design, made worse by vibration on broken-road duty.
Redesigned the joint to spread the load, added a gusset, and revised the weld procedure for that seam.
No cracking through an extended rough-surface fatigue run after the redesign.
Brake fade on long downhill duty
Loaded descents in the abuse cycle showed brake performance dropping off as the system heated up.
Brake sizing was adequate for flat-route duty but had little margin for sustained loaded descents.
Increased braking capacity and adjusted the friction spec, and documented a loaded-descent guideline for operators.
Stable braking held through the repeated loaded-descent test.
Rear suspension bottoming out when fully loaded
At rated load over the rough section, the rear suspension bottomed out and transferred shock into the frame.
Spring rate was tuned closer to a half-load case than to the rated maximum.
Re-rated the rear suspension for the loaded case and re-validated ride quality across the load range.
No bottoming out at rated load on the re-tested vehicle.
A Fault You Can Read About Is a Fault We Already Fixed
Most manufacturers only show you the wins. We think a buyer learns more from the problems — because the problems are where the engineering actually happens.
Every documented case follows the same path: testing surfaces it, we trace it to a root cause instead of patching the symptom, and the fix goes back into the standard build. By the time a model ships, the problems we caught are already designed out of it.
It also tells you how we will handle the problem we have not found yet — because there is always one. The process is the product.
Ask Us About the Hard Cases
If there is a failure mode that worries you for your routes or climate, ask. Our export team can tell you whether we have already tested for it — and what we found.