pdim : inverter testbed workshop chalmers university · the inverter has become a key component...

Confidential

PDiM : Inverter Testbed WorkshopChalmers University29/11/2018

2018/11/29 | 2Confidential

• What is a drivetrain inverter?

• Why testing the inverter?

• Requirements to test the inverter?

• The AVL inverter testbed

Agenda






Agenda


What is a Drivetrain Inverter?

E-motor

InverterSimplified

Electrical Powertrain


DC+

DC-

u

v

w

HVBattery

E-motor

Rotor positionsensor signals

ACPower

Electronics

Control circuit

Inverter

DC Link

Power Flow (Motor)Power Flow




HV Battery

Fuel Cell

LV Battery

E-Motor 6 Phase

E-Motor 3 Phase

Exciter Coil

Booster Cap

DC/DC Conv.

Picture:

Bosch

The inverter can have multiple power interfaces


“We plan to develop our own inverter mainly for two reasons :

1. The inverter has become a key component regarding safety, performance and drivability with big possibilities for optimizations and improvements.

2. 80% of the potential margin of the e-Drive (eMotor + inverter) is today in the inverter, not the eMotor.”

Customer statement:







Agenda


Why testing the inverter?

Field Failure

Detected

Resources deviated

from R&D toinvestigate

Identify affected

units

Recall already

sold units

Patch the units still in factory

Patch the units still at

dealers

Patch the recalled

units

A major failure was detected on the field, with several units already sold to the

customers


Process TimeEngineering Design

Design Validation

ProcessValidation

SOP


Flexibility in design changes

Fle

xib

ility in d

esig

n c

hanges


Process Time

Failure

Cost

Multip

lier

Engineering Design

Design Validation

ProcessValidation

SOP

Cost of a hardware design change as function of detection time


x1

x10

x100

x1000


Customer statement:

“If a failure requiring a change in the inverter hardware design exists,

each additional month passing without detecting it

multiplies by 10

the overall cost of the modification.

Having the possibility to detect a failure

6 months earlier in our development process

potentially saves 1M€…”




Process Time

Failure

Cost

Multip

lier

x1

x10

x100

x1000

Engineering Design

Design Validation

ProcessValidation

Field

Failure

SOP

ExtreemCriticalManageable Catastrophic

Failure Consequences

Ideal test and

validation zone






Agenda


Requirements to test the inverter?

INVERTER MOTOR

MOTORDATA

DRIVE TEST

Typical test setup

First level of complexity:Few common issues:

1. Is the eMotor available?

2. Is the eMotor validated?

3. Do the motor data fit 100% the eMotor?

4. What is the influence of the motor temperature during the tests?

Root cause:

The UUT is not isolated


E-Motor Supplier 2

E-Motor Data

Supplier 2

Requirements to test the inverter?

Inverter Supplier 1

Inverter Supplier 2

Inverter Supplier N

E-Motor Supplier 1

E-Motor Data

Supplier 1

E-Motor Supplier N

E-Motor Data

Supplier N

Second level of complexity:






Agenda


AVL Inverter Testbed : Power HiL based

E-motor

Inverter



Inverter

Real Power & Signal flows

E-Motor Emulator

Battery Emulator



GRID

EME

PSU EME

INT

BEM

EME = E-Motor Emulator

PSU EME = Power Supply EME

BEM = Battery Emulator

INT = INverter Table

Bidirectional

Energy flow

UUT

UUT = Unit Under Test


E-Drivetrain Testing Concepts

EME DC Supply

E-Power Analysis

Inverter TableCoolant

Conditioning System

E-Motor Emulator800A

Battery Emulator

Automation System

Fault Insertion Matrix



GRID

EME

PSU EME

INT

BEM

Bidirectional

Energy flow

FIM

Failure Insertion Matrix

UUT

DC AC

HV Failure Insertion Matrix



u

v

w

Phase to phase short circuit

Control circuit

DC+

DC-

DC L

ink


What if the phases get short circuited?Test case:



u

v

w

Phase to ground short circuit

Control circuit

DC+

DC-

DC L

ink


What if one phase gets connected to the ground?Test case:



What if the Rotor Signal gets noisy or lost?

Control circuit

DC+

DC-

DC L

ink


Test case:



Control circuit

DC+

DC-

DC L

ink


Rotor stuck 0rpm

What if the Rotor is blocked for a long period of time?Test case:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT

EME – E-Motor EmulatorPSU – Power Supply UnitBEM – Battery EmulatorFIM – Fault Insertion Matrix

EME 1000-400

INT

EME PSU250kW

Choose the maximum DC voltage

→ 600V | 1000V

BEM250kW

INT – Inverter TableUUT – Unit Under TestTCM – Testbed Config. MatrixCCH – Climatic Chamber

Scalable solution:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT


EME 1000-400

INT

EME PSU250kW


What is the maximum AC current?

→ 600V | 1000V

→ 400Arms | 800Arms | 1200Arms … upgradable

EME 1000-800

EME 1000-1200

BEM250kW


Scalable solution:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT


EME 1000-400

INT

EME PSU250kW



→ 600V | 1000V


What is the maximum power of the UUT?

→ 250kW | 320kW | 500kW | 640kW … upgradable

EME 1000-800

EME 1000-1200

EME PSU 500kW

BEM250kW

BEM 500kW


Scalable solution:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT


EME 1000-400

INT

EME PSU250kW



→ 600V | 1000V




Insertion of power fault needed?

EME 1000-800

EME 1000-1200

→ FIM … upgradable

FIM

EME PSU 500kW

BEM250kW

BEM 500kW


Scalable solution:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT


EME 1000-400

INT

EME PSU250kW



→ 600V | 1000V





Test under different climatic conditions needed?

→ INV replaced by Climatic chamber … upgradable

EME 1000-800

EME 1000-1200


FIM

EME PSU 500kW

BEM250kW

BEM 500kW

UUT

CCH


Scalable solution:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT


EME 1000-400

INT

EME PSU250kW



→ 600V | 1000V







EME 1000-800

EME 1000-1200


FIM

EME PSU 500kW

BEM250kW

BEM 500kW

UUT

CCH

48V application?

→ Add a LV eStorage … upgradable


Switch

BEMLV

Scalable solution:


Grid connection box


BiDirectional

Energy Flow

GRID

DCACSignal

Grid

UUT


EME 1000-400

INT

EME PSU250kW



→ 600V | 1000V







EME 1000-800

EME 1000-1200


FIM

EME PSU 500kW

BEM250kW

BEM 500kW

UUT

CCH

48V application?

→ Add a LV eStorage … upgradable


6 Phase application?

→ Add an EME … upgradable

EME 1000-400

EME PSU250kW

Switch

BEMLV

Scalable solution:



1

8

29

1

1USAChina

Germany

3

Racing

1

1

11

4

UK

Spain

AustriaRomania

Korea Japan

TaiwanIndia

Note: R&D High Voltage Inverter Testbeds only

Installed base:



Upgradable concept(future-proof)

Allows testing fault in a safe and repeatable

environment

The inverter is in the focus

The UUT is tested in its real power and signal

environment

The unknown variable of the environment are

eliminated from the equation

The test coverage of the inverter is more complete and more

efficient

The test setup is independent from the

eMotor

Proven solution

Summary of some advantages of the AVL inverter testbed architecture :

Confidential

Thank you for your attention!

pdim : inverter testbed workshop chalmers university · the inverter has become a key component...

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