inverter and e-motor integration and validation · 2018-07-06 · inverter validation process 14...

We Support the Automotive World to go Electric

28 June 2018

Inverter and E-Motor Integration and Validation

© SET Power Systems GmbH. All rights reserved2

Inverter – Motor Integration Process

© SET Power Systems GmbH. All rights reserved3

Inverter – Motor Integration Process

© SET Power Systems GmbH. All rights reserved4

Inverter – Motor Integration Process

© SET Power Systems GmbH. All rights reserved5

Inverter – Motor Integration Process

Automotive drive inverter have complexpower interfaces

9

HV

Battery

Fuel

Cell

LV

Battery

E-Motor

3 Phase

E-Motor

3 Phase

Exciter

Coil

Booster

Cap

DC/DC

Conv.

Picture:

Bosch

Inverter Design Process

10

Process Phase

SOP

Start of Production

Design Validation

6..10 month

specification

fulfilled?

ProcessValidation

6..10 month

production

process ok?

Engineering Design

Project Launch

Picture:

Bosch

Inverter Design Process

11

Engineering Design

Design Validation

ProcessValidation

SOP

Start of Production

Process Phase

6..10 month 6..10 month

➢ Validation cannot start before design freeze

Design Freeze

Boundaries:

➢ Practical approach: overlapping areas !!!

➢ In theory: linear process …Picture:

Bosch

Project Launch

‼ …. Risk & Costs

Inverter Design Process

12

Process Phase

Design Validation

6..10 month

ProcessValidation

6..10 month

Engineering Design

Project Launch

ExtremCriticalManageable

SOP

Start of Production

Failure Consequences

Picture:

Bosch

Stop and think

13

… No!

There is a strategy to

reduce risk & costs

Are you coping with the impossible?

Inverter Validation Process

14

Engineering Design

Design Validation

ProcessValidation

SOP

6..10 month 6..10 month

Start Of Project Design Freeze

Not influencible!

Start the “race” with a mature design!!!

➢ Realistic tests @ earliest possible state

➢ Remove the risk of unpredictable issues

➢ Find the weak points earliest possible

Picture:

Bosch

Test labyrinth

15

Signal-

HiL

Don’t get lost in the test labyrinth !

DC/AC

loads

E-Motor

& Dyno

Inductive loads

Test labyrinth

16

Signal-HiL

Inductive loads DC/AC loads

E-Motor & Dyno

No power flow

No recuperation

No fault testing

Power removed

Only 5% of electronics

“in-the-loop”

Models drive models

No realistic test setup

No dynamics

No fault testing

Original motor required

Dyno controls influences

Poor fault testing

Don’t get lost in the test labyrinth !

The way out of the Labyrinth

17

The way out of the Labyrinth:

Power-Signal Test Architecture

without Mechanics

EXIT

Inverter test system based on…

Start the „race“ with a mature design

18

Inverter Test with E-Motor Emulator (EME):

E-Motor TestbedChokes or blocked rotor

Cutting test time down by more than 90%!

DC/AC loads

Start the „race“ with a mature design

19

… means

Cutting test time down by more than 90%!

… means

Performing 10x more tests in the same time frame

Inverter Test with E-Motor Emulator (EME):

20

Remaining Errors

Engineering Design

Design Validation

ProcessValidation

!

Potential risk

Detection of errorswithout EME

More tests means less remaining errors

Effort /

test cases

More tests means less remaining errors

21

Remaining Errors

Effort /

test casesEngineering

DesignDesign

ValidationProcess

Validation

reduced risk

Detection of errorswith EME

Detection of errorswithout EME

Start the „race“ with a mature design

22

✓ Real motor not required

(change motor via mouseclick)

✓ Perfect tests of inverter controls

(Id/Iq, torque, speed, position)

✓ Easy fault injection testing

(functional safety ISO26262)

✓ Full power lab compatible

(road-to-lab)

… no delay, no installation

… no temperature drift

… stable operation @ 0rpm

… infinite fast ramps, high speed

… electrical & mechanical faults

… automatable & reproducible

… full power next to desk

… no mechanical hazards

✓ Inverter protection … adj. phase current limit

… adj. phase power limit

© SET Power Systems GmbH. All rights reserved23

Benefits of an E-motor Emulator

Customer Testimonials: Tier 1

28

LuK Schaeffler: Torque Vectoring Inverter Test (ASIL-D)

Further information: ATZelectronic 2015-06

… active short circuit test …short circuit shutdown

correct dynamics…!… phase short injection

Customer Testimonials: Tier 1

29

„The AVL Inverter Testsystem has provenitself as an ideal test tool. Within two weekswe could run a testprogram which used to take half a year! “

Customer Testimonials: OEM

30

How Mercedes India challenges Silicon Valley

AVL Inverter Testsystem

https://www.welt.de/motor/article159733767/Wie-Indien-dem-Silicon-Valley-den-Rang-ablaeuft.html (27.11.2016)

"We make sure that new cars drive longer andlonger in the virtual world, before we need actualprototypes. That increases the flexibility in development, accelerates the processes andreduces costs on top of that.“ (Manu Saale, Die Welt,

27.11.2016)

"Not for nothing have we set up a testbed in thecellar, which can simulate any electric motor[AVL‘s Inverter Testsystem], long before it isavailable at all as a prototype.“ (Thomas Weber, Die Welt,

27.11.2016)

Customer Testimonials: OEM

31

Daimler: Full road-to-lab for complex inverter controls testing

Further information: ATZelectronic 2013-031

E-motor emulator is partof the „virtual car“

Inverter control loop test forsmooth traction …

in office area @ full power!

Your situation?

32

Is your inverter test concept- efficient ?- realistic ?- fast ?

Basic P-HiL Based Inverter Test System

33

Energy -

Encoder &Resolver signals

PowerSupply

UUT-Inverter

12V Low Voltage

BatteryEmulator

E-MotorEmulator

SafetyControlSystem

Cycle

Bi -

Directional

Grid

Professional P-HiL Based Inverter Test System

34

Energy -

Encoder &Resolver signals

UUT-Inverter

BatteryEmulator

SafetyControlSystem

Cycle

Bi -

Directional

Grid

Tools

Automation System

Grid

FaultInsertion

Rack

Encoder &Resolver signals

UUT Table

12V Low Voltage

PowerAnalyzer

CoolantConditioning

DC/DC Load

ClimaticChamber

E-MotorEmulator

PowerSupply

© SET Power Systems GmbH. All rights reserved35

Thank you very much for

your attention!

Modified from S. Gross, CN Collection