Electric Vehicle Motor and Controller Test

Posted by Gianmarco 09-04-2019 0 Comment(s) 5165 Testen en Meten,

Each year vehicle electrification continues to increase, with all signs pointing to this trend accelerating in the future. Some of the factors contributing to this development are the increasing use of hybrid and fully electric vehicles to meet “green energy” goals, the desire for the greater reliability that electronic components generally provide and the need to reduce automotive recalls.

Electric Motor and Drive-train (Electric Mobility) Testing is a critical part of bringing any electric drive-train into production. In this paper the requirements for an electric drive-train test cell are discussed. The implementations of such test cells are described, and examples of test results are provided. The energy and power requirements for three- phase motor and controller, Unit Under Test (UUT) connected through a common dc bus are described.
The data used represents various steady state load conditions during durability test cycles. This “Smart Green Technology” concept not only reduces the energy requirement from the grid but also eliminates the inefficiencies by putting energy back on the grid.

This application note provides an example of testing an E-Motor and Controller for electric vehicles. Traditional test setups require a dedicated DC source and Load in parallel to deal with bi-directional energy flow. This can require a complex test setup to coordinate energy flow and to avoid damaging expensive test equipment.

The PSB 9000 is a bi-directional DC source and electronic load which simplifies the test setup, avoids catastrophic damage and decreases test times. This electronic load has the unique option of back-feeding converted energy into the grid.

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Model	Maximum Voltage	Maximum Current	Maximum Power
PSB 10060-1000	60 V	1000 A	30 kW
PSB 10080-1000	80 V	1000 A	30 kW
PSB 10200-420	200 V	420 A	30 kW
PSB 10360-240	360 V	240 A	30 kW
PSB 10500-180	500 V	180 A	30 kW
PSB 10750-120	750 V	120 A	30 kW
PSB 11000-80	1000 V	80 A	30 kW
PSB 11500-60	1500 V	60 A	30 kW
PSB 12000-40	2000 V	40 A	30 kW