David Meek. Engineering Director Intertek Transportation Technologies. Sponsors

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1 David Meek Engineering Director Intertek Transportation Technologies Sponsors

2 NEW DEVELOPMENTS IN HIGH VOLTAGE EV SYSTEMS TESTING Innovations in Testing and Data Acquisition Dave Meek Engineering Director Intertek Transportation Technologies, UK 6th September 2017

3 DELIVERING TOTAL QUALITY SOLUTIONS OUR SECTORS Products OUR SERVICES Assurance Testing Inspection Certification Trade Resources THROUGH A DEPTH AND BREADTH OF ATIC SERVICES 3

4 AGENDA 01 Transportation Technologies Worldwide 02 Transportation Technologies UK 03 New Developments in EV Systems Testing 4

5 01 TRANSPORTATION TECHNOLOGIES WORLDWIDE

6 A GLOBAL AUTOMOTIVE FOOTPRINT North America: Detroit, MI Grand Rapids, MI San Antonio, TX Pittsfield, MA Phoenix, AZ Irvine, CA EMEA: Milton Keynes, UK Kaufbeuren, DE Griesheim, DE Geleen, NL Johannesburg, S.A. APAC: South America: Valparaiso, Chile Shanghai, China Guangzhou, China Chongqing, China Bangkok, Thailand Taipei, Taiwan Seoul, South Korea Matsuda, Japan TT employees 11 countries Powertrain, Battery, Electrical Safety, EMC, Lubricant & Fuel, Materials, Fleet Robustness, Infotainment 6

7 02 TRANSPORTATION TECHNOLOGIES UK

8 MILTON KEYNES FACILITY DEVELOPMENT TIMELINE 2012 Intertek purchases Tickford Powertrain Test Ltd Six new high capacity engine test cells commissioned Awarded Test Facility of the Year V EV drive systems test facilities commissioned Two hybrid powertrain test cells commissioned 2017 Two additional hybrid driveline rigs commissioned HV BISG climatic rig commissioned Six P&E test cells upgrades Customer driven expansion and enhanced capability Further Hybrid and EV test capability

9 MK POWERTRAIN TEST FACILITY TODAY 30 Cell Powertrain Test Facility EV Systems Testing to 1000V 3 cells Engine Performance, Emissions and Mapping transient dynos to 570kW / 4000Nm 8 cells Hybrid Powertrain and EV Driveline Testing 4 cells Engine Durability Testing to 900kW / 6000Nm 4 cells Catalyst, DPF, SCR and GPF Ageing 5 cells Fuel Additive Engine Testing 6 cells Transmission Testing stand-alone or fired engine Real Driving Emissions Testing (PEMS) 9

10 03 NEW DEVELOPMENTS IN EV SYSTEMS TESTING

11 INNOVATIONS IN EV SYSTEMS TEST High Voltage Belt Starter/Generator system test rig with integrated Cold Chamber High Voltage Systems Functional Test Bench In-house developed HV Electrical Power Analysis system ECE Reg. 85 compliant emotor certification test rig

12 HIGH VOLTAGE E-MACHINE TESTING New 100kW emachine Dynamometer Rig HV Belt starter/generator systems testing Main features Dyno capacity: 100kW, 110Nm, 18,000rpm High voltage DC Battery Simulator High bandwidth in-line HBM T40B torque sensor with UKAS torque calibration traceability to < 0.05% High frequency data acquisition 20kHz to 20MHz depending on channel Trunnion mounted BISG machine cradle with reaction torque measurement system -25oC cold chamber CAN & Flexray gateway for Inverter control & data acquisition Test applications emachine & inverter controls de-bug and optimisation Performance measurment Machine and inverter efficiency mapping Cold climate evaluations 12

13 HIGH VOLTAGE E-MACHINE TESTING BISG System Dynamometer Rig Key Innovations: In-house developed 3.0kV galvanically isolated high frequency data acquisition system 3.0kV isolated input cards 1.0MHz integrated multi-channel data acquisition Optically isolated Ethernet link to control room interface Trunnion mounted BISG machine cradle with reaction torque measurement system Combination of dyno mounted HBM in-line torque sensor and BISG machine pully torque measurement enables belt losses to be calculated -25oC cold chamber Air refrigeration to -25 C Fluid refrigeration to -45 C Heated load cell for reliable torque measurement at low temperature 13

14 HIGH VOLTAGE EV SYSTEMS TESTING New HV Functional Test Bench Simultaneous multiple systems test capability DC Charger, AC Charger, DC:DC Converters, Fuse and contactor systems Key features: DC Sink/Source 2 x 32kW modules May be linked in parallel or series up to 1000V Battery or DC charger emulation Variable AC Source 12kVA / 0-680Vac HV passive load bank with rapid load step capability AC grid emulation with frequency and voltage variability For DC:DC converter testing HV DC active load bank High precision, low noise active DC load bank DC:DC converter testing EVSE DC Fast Charger Comprehensive high frequency data acquisition & power analysis 14

15 HIGH VOLTAGE EV SYSTEMS TESTING HV Functional Test Bench Modules High Precision Multi-meter HV Active Load Bank 200MHz Oscilloscope HV DC Passive Load Variable AC Source Precision 3-Ph AC Power Analyser DC Fast Charger 2 x 32kW DC Sink/Source Modules 15

16 HIGH VOLTAGE EV SYSTEMS TESTING New Flexible Electrical Power Analyser In-house designed and manufactured Key features: Modular construction Each I/O module has 3.0kV galvanic isolation 19 Rack mount architecture Modules developed: HV differential voltage input LV differential voltage input Current via LEM sensor input System Capability Up to 1.0Mhz bandwidth 16 bit resolution Noise rejection hardware architecture In-house developed software Power calculation in real time with 0.5sec. averaging Output CAN or analogue 16

17 EV SYSTEMS TESTING Test Applications Control systems software de-bug and optimisation System communications testing Thermal tests Fault response evaluations Performance measurement Efficiency measurement 17

18 HIGH VOLTAGE EV SYSTEMS TESTING ECE Reg. 85 Certification Facility VCA Accredited facility VCA Accredited for pre-certification attribute setting (Various critical parameters must be pre-specified and submitted to the VCA for validation/approval before the actual certification occurs) VCA Accredited to perform Reg.85 power certification for emotors (1st Uk accredited facility) UKAS traceable measurement for all test data sources Intertek emotor test facility easily exceeds all certification accuracy requirements 18

19 EV SYSTEMS TESTING Summary Innovation and investment delivered in the UK by Intertek Increase in EV systems test capacity in 2017 One of the UK s leading independent EV systems test suppliers Part of a wider Intertek network including machines, batteries and electronic systems testing and certification Supporting the UK and European low carbon automotive industry 19

20 THANK YOU! Dave Meek Engineering Director Intertek Transportation Technologies 8 Tanners Drive, Milton Keynes, UK Tel INTERTEK ALL RIGHTS RESERVED. No reproduction of this material is allowed without written permission of Intertek.

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