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