Closing the Test Gap Advanced Testing of Traction Invertersthe+Test+Gap... · • Concurrent engineering issues (component availability …) Fault simulation requirements (realistic,

© SET Power Systems GmbH Page 1

DRIVE INVERTER TESTING CHALLENGE

Closing the Test Gap –

Advanced Testing of

Traction Inverters



WHERE IS THE

TEST GAP ?


Common Requirement Management

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Chassis Dyno

Office Sim

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Consistent and comparable Results

Road Testing

MIL/SIL Tests

E-Motor TB

HIL Tests

Complexity of steps not balanced!



Common Requirement Management

Chassis Dyno

Office Sim

Consistent and comparable Results

Road Testing

MIL/SIL Tests

E-Motor TB

HIL Tests

pHIL™ Virtual

E-Motor

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POWER-HIL CLOSES THE GAP


TEST SETUP ?

Inverter Under Test

Typical traction inverter test issues today:

• Concurrent engineering issues

(component availability …)

• Fault simulation requirements

(realistic, reproducible, automatable …)

• Load matrix verification

(max torque @ 0rpm, fast power cycling …)

• System integration testing

(functional safety ISO26262 …)

• Front loading

(advanced controls, road-to-lab …)

• Field return analysis

(replay specific test conditions …)



E-Machine Emulator

Technology (pHILTM)

E-MACHINE EMULATION TECHNOLOGY


Virtual

load

torque

Uzw Czw

+

-

ia

ib

ic

Antriebsumrichter (Prüfling)

G1

G2

G3

G4

G5

G6

Drehgeber Interface

SensorenSteuerung/ Regelung

Gate Treiber

Signale

Power- supply

Power- supply

pHIL™ Virtual E-Motor

Inverter under Test




Fundamental requirement:

„True motor characteristics“ i.e.

Power-HIL must mimic an E-motor at all

operational points of interest

True electrical power flow emulated

Simulated machine mechanics



True El. Power Flow: Basic Test System Topology with Energy Loop



Power-HIL Technology MUST Mimic Correct Machine Characteristics

Flux-based machine model includes

non-linearities and operates at 3MHz

Highly realistic back emf reproduction

(blue = real motor, red = pHIL™)




Fundamental requirement:

„True motor characteristics“ i.e.

Power-HIL must mimic an E-motor at all

operational points of interest

True electrical power flow emulated

Simulated machine mechanics

Fundamental solution:

Extreme „oversampling“ technology

(50..100 times faster than a typical

drive inverter phase signals) &

Precise Flux-based machine model

12V/1kW 800V/350kW



Emulator (PHIL) Advantages:

Mimics electrical motor interface

No mechanics (no rotating parts)

Motor is a software model

Provides full fault stimulation

Easy automation

Protection for inverter under test

Compatible with labs / office area

Motor modification online at runtime




CUSTOMER EXAMPLES:

HOW PHIL CLOSED

THEIR TEST GAPS!



Typical traction inverter test issues today:

Concurrent engineering issues


• Fault Simulation Requirements


• Load Matrix Verification

(max torque @ 0rpm, power cycling …)

• System Integration Testing


• Field Return Analysis


Front Loading


OEM 1

EXAMPLE

CLOSING THE GAP – EXAMPLE 1


OEM – Project Objectives:

Provide test setup for advanced inverter controls verification.

Tests on active damping of hybrid drivetrains is to be

transported from road testing into lab testing.

No decision for dyno: • Office location compulsory

• Seamless operation requested

• Too high dynamic requ. (harm.)

No decision for HiL: • Real power flow required

• Machine models too slow

• Inverter instrumentation not

acceptable

pHIL™ Virtual

E-Motor



How Power-HIL closed the gap:

100kW DC source/battery emulator

160kW virtual electric motor (pHIL™)

Compact power HiL system at OEM 1

pHIL™ Virtual

E-Motor



Results & Conclusions:

Full power test of active damping in the lab (office)

Cost & time savings due to frontloading road-to-lab

Successful validation of the power HIL methodology (compared to real motor)

pHIL™ methodology to be incorporated into OEM’s design process

Complex control loop optimized pHIL™ Virtual

E-Motor



See also:

This project is explained in

ATZ-Electronic.

Download of article via

www.set-powersys.de



• Fault simulation requirements


Automotive traction inverter testing is challenging today

Concurrent Engineering Issues


• System Integration Testing


Front Loading


Field return analysis


Load matrix verification


OEM 2

EXAMPLE



OEM – Project Objectives:

Provide a test environment for End-Of-Line inverter testing

which allows advanced testing of:

- complete load matrix

- motor/harness fault insertion

Provide capability to generate a data base for inverter field return analysis.

n [min-1] M [Nm]

t [s] t [s]

Artemis - Rural

[km

/h]

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0 200 400 600 800 1000 1200

-250

-200

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-100

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0 200 400 600 800 1000 1200

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0 200 400 600 800 1000 1200

Ge

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Dre

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tD

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min

-1]

[Nm

]



How Power-HIL closed the gap:

pHIL™ integrated into a fully automated End-of-Line test system

Photo source: SOMA/Zollner



Results & Conclusions:

Automated load matrix and fault testing

Generate a data base for inverter field return analysis



Concurrent Engineering Issues


Front Loading


Field Return Analysis


Load Matrix Verification


System integration testing


Automotive traction inverter testing is challenging today

Fault simulation requirements


TIER1 SUP

EXAMPLE



Project Objectives:

Provide an test-environment for a SIL-D classified automotive drive inverter

• Test of safety functions

• No test specimen modification

acceptable (HW & SW)

• Robustness testing with

specimen protection

• Test of complex operational

points and fault handling



Rotor Sensor Fault Injection Tests (Tamagawa-Type):

Various Wire breaks

Signal Noise Injection, EMV Peaks Injection (not shown)

Various Rotor Sensor Miss-Alignments (not shown)



Fast Recuperation Test at High Rotor Speed

from shaft torque +250Nm to -250Nm and versus vice

check of Id and Iq control characteristics



Chassis Dyno

Office Sim

Road Testing

MIL/SIL Tests

E-Motor TB

HIL Tests

pHIL™ Virtual

E-Motor

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Pumps

(Fuel, Oil, …)

Electrical

Brake

Power Steering

Fans

Your

Application ?

… ALSO FOR LOW POWER & AUX


Thank you for your Attention

pHIL™ Virtual

E-Motor

Power HIL closes the gap

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Documents

Closing the Test Gap Advanced Testing of Traction Invertersthe+Test+Gap... · • Concurrent engineering issues (component availability …) Fault simulation requirements (realistic,