the challenges of e-drive & its validation
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The Challenges of e-Drive & Its Validation
William Chang
Chroma ATE Inc.
2019/6
E: [email protected] W: www.chromaate.com
1 iEVTech 2019, EVAT
Agenda
1. Technology in e-Drive
2. Validation Requirement
3. Validation Tool
4. Conclusion
2 iEVTech 2019, EVAT
e-Drive Configuration
Battery Motor Gearbox MCU
(Inverter)
DC/DC
OBC
BDU
EVSE
Electric Drive Configuration
Ju
nctio
n
Bo
x
BMS
Power Electronics Mechanical Parts
3 iEVTech 2019, EVAT
e-Drive Design Criteria
Reliability & Safety
•Protection
•Component Quality
•Validation & Safety Compliance
4 iEVTech 2019, EVAT
EV Power Electronics Technology Index
Design Target Index
• DSP-based Control
• Intelligent Drive Control Circuitry
• Cooling System
• Regenerative Braking
• CAN-bus Interface
• Advance Power Protections
• Light Design (20kW/kg)
• High Power Density Design (20kW/L)
• Quick Response (100ms)
• High Efficient Cooling (150W/cm2)
• High Reliability (>15 years, >150K km)
5 iEVTech 2019, EVAT
V-model of Automotive Product Development Le
vel o
f In
tegr
atio
n
Requirements
Design & Simulation
Sales & Aftermarket
Testing & Validation
Integration & Implementation
Level of Maturity
Component/Part
System
Vehicle
Verification & Validation
7 iEVTech 2019, EVAT
Force Stress Analysis (V-Component Level)
Integration & Vibration Verification
656Hz
Frequency (Hz) Power Spectral
Density
10 20
55 6.5
180 0.25
300 0.25
360 0.14
1000 0.14
8 iEVTech 2019, EVAT
Verification (V-System Level)
Function Test
1. DC Bus leakage current Test
2. HV over voltage protection
3. Contact resistance Test
4. Thermal protection Test
5. Rated/peak current Test
6. LV under voltage Test
7. Burn-In Test
8. Hi-Pot Test (2000Vac, <1mA)
9. Insulation resistance (600VDC,>10Mohm)
10. No load 1000rpm Test
11. Motor lock test
12. Dynamometer test
Auto Testing Equipment (by Chroma) 1000A by pulse/500A 30sec
Support MES Interface.
Report analysis
Auto Testing
9 iEVTech 2019, EVAT
Elaboration Phase - SW Development Safety
AUTomotive Open System ARchitecture.
Application Software
Hardware
Application Software
Hardware
Standardized
HW-Specific
Using standards -Communication Stack
-Diagnostics
-CAN
Customer Needs -Adaptive Cruise Control
…
Ref : Rebeca D.” AUTOSAR software Overview” ., Sep. 2017
10 iEVTech 2019, EVAT
ISG Controller Battery
BMS Inverter
DC/DC
BDU
OBC
EV Power Electronics
Battery Disconnect Unit
EREV ISG Controller
Battery Management System
Motor Controller (Low Voltage )
BEV Motor Control Unit PHEV Motor Control Unit
Jun
ction
b
ox
12 iEVTech 2019, EVAT
Motor Control Unit (Inverter)
20kW 40kW 60kW 80kW 100kW Continuous Power
200kW
Peak Power
150kW
100kW
50kW 40/25kW
80/35kW
180/70kW
105/45kW
150/60kW
LSEV
Passenger Car
SUV/Commercial
Performance/Minibus
200/90kW
13 iEVTech 2019, EVAT
Power Electronics Module (PEM) for Tesla Roadster
Optimized manufacturability and reliability
EOL test by Chroma ATS
0% IQC failure with 5000+ units shipped
Customization satisfaction
2007
14 iEVTech 2019, EVAT
Inverter & BMS for Passenger EV
S3 EV+
SOP:2017, Q4
LUXGEN S3 EV+ Specification
Acceleration (0~100kph) 7.2sec
Speed 147 km/h
Continuous Power 45kW
Peak Power 150kW
Climb > 34%
Energy Consumption EV : ~ 130Wh/km
Driving Range BEV: 220 km
Motor Control Unit BMS
+
15 iEVTech 2019, EVAT
Dual-mode Motor Control Unit for PHEV
插電式混合動力新能源車
SUV
SUV Specification
Acceleration (0~100kph) ~ 11.4 sec
Speed 147 km/h
Driving Motor Peak Power 105kW
ISG Peak Power 47kW
Climb > 34%
4 Modes BEV、Regen、Acc.、High Speed
Driving Mode Driving Mode BEV
Energy Consumption Energy
Consumption ~ 206Wh/km
Driving Range Driving Range 55 km
Dual Mode MCU
16 iEVTech 2019, EVAT
Low Voltage Motor Controller
Features: Applicable for IM, PM, BLDC motor
Auto-learning motor control algorism
MPTA function for extra torque
High power density & efficiency
Compact size for easy installation
Application \ Model CR10 CR15
e-Scooter ●
e-Motocycle ● ●
Micro EV ●
eTruck ●
eForklift ● ●
UTV ● ●
ATV ● ●
Sightseeing Car ● ●
eJeepney ●
eTrike/3W ●
Golf car ●
Go-Kart ●
19 iEVTech 2019, EVAT
xEV Safety Requirements
EV Safety
Vehicle Safety
Driving & Comfort
Motor
Power Electronics
Battery
Charging Station
Collision safety Electric safety Network safety
Dynamic performance Power consumption Driving range
Performance Environment test Electric Safety
Electric safety Regulation compliance Interoperability
Charge & discharge Real-time monitoring Auto protection
Performance Environment test Protection & Reliability
20 iEVTech 2019, EVAT
Verification for EV Drivetrain Component
What testing equipment are available?
21 iEVTech 2019, EVAT
Electrical Vehicle Test Solutions
BMS PCBA ATS HCU(VMS/VCU)
ATS
Battery Pack
ATS
Regenerative Battery
Module/Pack
Test System
Charger Station (EVSE) ATS
Electrical Safety
Analyzer
DC-DC Converter
ATS
AC Charging
Compatibility ATS
Regenerative
Battery Cell Test
System
Motor Stator
Test System
Wireless Charger ATS
22 iEVTech 2019, EVAT
Power Electronics Unit/Inverter & Board Level ATS
Traction (Motor) Driver Open Loop Test: components, circuit, temperature test.
Control board Driving board
23 iEVTech 2019, EVAT
OBC & DC-DC Converter Test Solution
- Built standard test items, meet GB/T & QC/T test requirement, CAN
communication included. Suitable for Certification Lab & Production Line.
中国汽车技术研究中心
法雷奥
The rights of above referenced trademarks belong to each registered company.
24 iEVTech 2019, EVAT
AC/DC EVSE(Electric Vehicle Supply Equipment) Test Solution
- Meet IEC/SAE/GB/CHAdeMO…etc test requirements cover the EV charging
regulation worldwide & provide standard test items
中国汽车技术研究中心
The rights of above referenced trademarks belong to each registered company.
25 iEVTech 2019, EVAT
New
EV Wireless Power Transfer(WPT) Test System
- Meet SAE & GB/T test requirement, include
• Eff. & Misalign. Coefficient
• Magnetic Field
• Surface Temperature / FOD Test
XYZ Positioning Device
The rights of above referenced trademarks belong to each registered company.
26 iEVTech 2019, EVAT
EV Drivetrain Test : Dynamometer
Power: 250kW,
Speed: 15,000 rpm
Torque: 500 Nm MCU (Driver) Motor
HIL (hardware-in-loop)
27 iEVTech 2019, EVAT
Automotive Electric Safety Test Solution
联合汽车电子 大陆汽车
德尔福 博世电子
特斯拉(美国)
The rights of above referenced trademarks belong to each registered company.
28 iEVTech 2019, EVAT
Battery Test & Automation Solutions
Cell Formation
Module/Pack
Cell Reliability Test
HT Aging
Barcode
Binding
Formation Grouping
OCV & ACR Test
RT Aging
Applications
Battery cell semi-finished product
Battery cell
Super capacitor
Battery management system
Battery module
Battery pack
Battery Cell Automated Test Systems
Battery Cell Insulation Tester
Battery Cell Barcode Binding Equipment
Regenerative Battery Cell Formation System
Battery Cell OCV & ACR Test Equipment
Battery Cell Grouping Equipment
Battery Charge/Discharge Test System
Battery Module/Pack Automated Test Systems
Battery Cell Simulator
BMS PCBA ATS
Battery Module/Pack Functional ATS
Regenerative Battery Module/Pack Test System
Battery Module/Pack ATS
Battery Module/Pack Maintenance ATS
29 iEVTech 2019, EVAT
Battery Pack Test Solution
17040 60KW – 300KW ,
Max: 1000V
17030 above 300kW/ 1500V
17020 5KW – 60KW
Max: 500V
- Charge and Discharge Test System
30 iEVTech 2019, EVAT
HIL (hardware-in-loop) Test Solution
Battery Pack HIL Dyno for Powertrain HIL Other HV Testbed HIL
31 iEVTech 2019, EVAT
Take Away…
1. For EV power electronics, power density, performance, cost, and reliability are
important, among them, the safety is utmost critical.
2. Unlike gasoline cars, xEV technologies are still new and lack of long-term
safety validation record.
3. To identify potential risks and error through continuous effort of testing and
validation.
4. Automatic test system can not only increase the test item coverage and
speedup the R&D process in EV component developing stage, but also
conduct end-of-line test in the mass production stage to ensure the
performance and quality of the products.
The devil is hidden in the details.
33 iEVTech 2019, EVAT
Company Profile
Founded 1984.11.8
Paid-up Capital US $138.9 Million
IPO 1996.12 (TAIEX : 2360)
Chairman & CEO Leo Huang
Employees Global 2,444; Taiwan 1,716 (2019.01)
Revenue US $ 251.6 Million (2018)
US $ 564.4 Million (2018 Consolidated,)
Headquarter Taoyuan, Taiwan
Products: Test & Measurement Instruments
Automated Test Systems
Intelligent Manufacturing Systems
Test & Automation Turnkey Solutions
Harvard Business Review
The Taiwan Top 50 Best Performing
CEO, 2018 (Ranked No. 14)
34 iEVTech 2019, EVAT
Vision & Mission
Chroma provides test & automation turnkey solutions for customers
to ensure the performance and quality of their products.
◆ Precision
◆ Reliability
◆ Uniqueness
World-class Products World-class Enterprise
◆ Innovative Technology
◆ “Chroma” Brand
◆ Globalization
35 iEVTech 2019, EVAT
Global Operation Sites
48 Operation
Sites
96 Distributors
Netherlands:
Ede
Quantel:Singapore
Taiwan: Taoyuan (Headquarters)
EST. 1993 EST. 2001 EST. 1999 EST. 2017
EST. 2016
EST. 2003
Japan:
Shin-Yokohama/
Nagoya/ Osaka
EST. 2008
Korea:
Pangyo
China/ Xiamen China/ Chongqing
EST. 2011 EST. 2011
EST. 2018
United States:
Irvine, CA
Santa Clara, CA
Chandler, AZ
Allentown, PA
Albany, NY
United States:
Foothill Ranch, CA
Marlborough, MA
Detroit, MI
Mexico:
Ciudad Juarez
Others: Qingdao/ Zhengzhou/ Xian/Hefei/ Chengdu/ Wuhan/ Hangzhou/ Changsha/ Guangzhou/ Hong Kong
Germany:
Augsburg
Others:
India: New Delhi/ Mumbai/ Bangalore
Thailand: Bangkok
Vietnam: Hanoi/ Ho Chi Minh
Malaysia: Kuala Lumpur/ Penang
Philippines: Manila/ Cebu
Indonesia: Jakartar
EST. 2009 EST. 1998
China/ Shenzhen
EST. 2006
China/ Suzhou
EST. 2000
China/ Shanghai
EST. 1999
China/ Beijing
EST. 2001
China/ Dongguan
Taiwan: Hsinchu Taiwan: Kaohsiung
36 iEVTech 2019, EVAT
Production Base
Headquarters &
Taoyuan Factory
Kaohsiung Factory New Headquarters &
Taoyuan Factory
55,667 m2
Production Line:
AI Line, SMT Line,
PCBA Line,
Module Line,
Instrument & ATS
Assembly Line,
Mechatronics System Line
13,469 m2
Production Line:
Mechatronics System Line
104,141 m2
(2020.1H)
ISO 9001/9002
IATF 16949:2016
ISO/IEC 17025
ISO 13485
37 iEVTech 2019, EVAT
FPD/ Video & Color
Power Electronics
Passive Component & Electrical
Safety
Semi- conductor
/ IC
LED/ Lighting
Photovoltaic
Electric Vehicle
Battery
IMS & AI
Photonics & AOI
Product Mix
Automation
Integration
Test &
Measurement
IMS
38 iEVTech 2019, EVAT
Test & Automation Turnkey Solutions
• Test Instruments
• Automated Test Systems
• Turnkey Solutions
解決方案
40 Product Lines
618+ Models
39 iEVTech 2019, EVAT
Research & Development
0
50
100
150
200
250
300
2014 2015 2016 2017 2018
25.2 26.1 31.2 36.2 38.1
171.2 151.3
241.1
267.3 251.6
R&D Expenditure
Revenue R&D Expenditure
US$ Million
14.7% 17.3% 13.0% 13.5% 15.1%
Employee Distribution
(by Function)
R&D Expenditure/
Revenue
R&D
MFG
SALES
MGMT
125
414
444
684
40%
QC 49
Total
1,716
40 iEVTech 2019, EVAT
Technology Accomplishments
100 891
Core Technologies Patents, Worldwide
515
Patents, Taiwan
• Top 100 in overall rankings
• Ranked No.1 in Test & Measurement
industry
41 iEVTech 2019, EVAT
Customer Satisfaction
The rights of above referenced trademarks belong to each registered company