Titel

VALIDATION OF THE COMPLETE DRIVELINE

KEY BENEFITS OF FEV E-MOBILITY TEST BENCHES

> State-of-the-art solutions> Solutions based on robust and validated products> Flexibility and scalability of MORPHEE®: A test bed that follows changes in technologies

> E-axle test benches

In this configuration, this is not only the e-motor that is tested but the complete drive chain. It permits, in the downstream steps of the development, to test the complete system. The calibration of the inverter is done, with the goal to increase the global efficiency of the system. Power analysis is needed.

FEV operates, plans and implements state of-the-art e-axle test beds. This involves the use of FEV dynamometers and conditioning systems, as well as tailor-made solutions for customer-specific requirements. Here again, the MORPHEE® automation system offers a high degree of flexibility and simple configuration for various e-axle test beds types.

Solutions for characterization, optimization and durability for E-motor and E-axle, powered by MORPHEE®

E-MOTOR and E-AXLE TEST BENCHES

Considering e-motor testing, decisive differences from combustion engines can be found in the use of current as the drive power and in the far higher rotational speeds of electric motors. Few years ago, the maximum rotational speed was limited to about 15,000 rpm. At present, FEV e-motor test bed solution reaches rotational speeds of of 20,000 rpm and above. Other configurations are also possible: FEV proposes solutions where the components are tested together, and as closely to reality as possible, in the context of a system test. In this context, it is necessary to consider both hybrid drives, meaning the integration of electrical components into the powertrain, and purely electric drive concepts. In addition to traditional drive concepts, there is now a so-called “E-axle” coming into play. This involves a highly integrated electric drive unit, arising from the combination of an electric motor, transmission, inverter and control unit.

With FEV test bed solutions, boost the efficiency of your test center.

E-MOTOR CHARACTERIZATION> High-speed e-motor test benches

E-motor testing aims to characterize the e-motor and the inverter, in the upstream steps of development. This requires to be as close as possible from the real conditions, such as the climatic ones – in that case, a climatic chamber is used – or the driving in itself – models simulating the driver, the road…. The key factor considering this type of test bed is its ability to test at very high speeds and highly dynamically. Vibrations are to be considered. FEV designs and industrialize e-motor test beds. FEV dynamometers and FEV conditioning systems are part of the solution, as well as tailor-made solutions for customer-specific requirements. The MORPHEE® automation system offers a high degree of flexibility and simple configuration for various test beds types. At present, FEV has built e-motor test bed solutions that enable rotational speeds of 20,000 rpm and above.

CHARACTERISTICS OF FEV E-MOBILITY TEST BENCHES

> MORPHEE® for E-mobility (Automation, Simulation and Calibration)> Preferred models for electric drive chains> Various architectures evaluated> EtherCAT > ECoolCon for Water and oil conditioning with 1…3 circuits, with automatic fill and drain> OSIRIS® power analyzer> Battery simulator

Dynamic E-motor test bench of 20 000 rpm and above: good accuracy for speed control for low speed (0...10 rpm) E-axle test bench: maximum speed usually 2 500 rpm, with 3000 Nm for the torque

E-MOTOR AND E-AXLE

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FEV test beds solutions

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WHAT CAN YOU DO WITH FEV SOLUTIONS?

> Characterization of the inverter and the e-motor: it permits to build models, that will be then used in the future steps of development, for the definition of the Control Laws of the EMS (Energy Management System), for hybrid applications and as well for pure electric applications.> Optimization of the efficiency of the e-powertrain, considering several use cases (motorway, urban, rural), with the calibration of the inverter: voltage and current signals, frequency versus angular position and speed, transient torque management, … > Durability tests, with mechanical cycles - vibrations, reducer, differential - and thermal shocks - cooling, rotor thermal management…> Validation of the driveline> Benchmark between different e-motor or hybrid powertrain

FEV PRODUCTS: A MUST FOR YOUR E-APPLICATIONS

> MORPHEE®, as the cornerstone of e-motor and driveline optimization as well as EMS calibration. With it, rotor and stator thermal management operations: derating operations, to prolong the e-motors life and keep the vehicle’s autonomy at an acceptable level during its complete life.

> OSIRIS® Power Analyzer: OSIRIS® measures and analyze the efficiency of the e-powertrain system by measuring the power before and after the inverter, and before and after the e-motor.

> eCoolCon, the FEV conditioniong unit for temperature control in e-axles, in hybrid drive trains and in e-mobility batteries. The perfect solution for stable experimental conditions that will enable you to reduce test bench time.

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FEV Software and Testing Solutions GmbH Brehnaer Strasse 3 | D 06188 Landsberg / SaalekreisTel.: + 49 241 5689- 0 | Fax: +49 241 5689-119 sales@fev.com | www.fev.com