Dynamic Drive Motion for Testing Applications Presented by James Ellis Manufacturing in America March 14-15, 2018

Transcription

1 Dynamic Drive Motion for Testing Applications Presented by James Ellis Manufacturing in America March 14-15, 2018

2 Before we start A Penny for Your Thoughts At the end of the session, share your feedback via MiA App - and get a chance to win tickets to the Detroit Tigers baseball game!

3 Its All About Me James Ellis - Strategic Business Development Siemens Digital Factory - Motion Control BS Mechanical Engineering - Oakland University MBA - University of Toledo 15+ years developing solutions for manufacturing and industry. 3+ years with Siemens delivering motion control solutions for advanced test applications.

4 Question What is currently the largest disruptive technology in automotive powertrain development and how does this impact testing/validation? Electric Vehicle (EV) Technology In the U.S. EV sales increased by 21% in 2017 General Motors plans for 20 new EVs by 2023 Ford is investing $4.5 billion into 13 new EVs. Toyota plans to electrify entire lineup by 2025 Volvo announced all models after 2019 will be hybrids or all-e In total, the automotive industry is expecting 127 batteryelectric models to be introduced over the next five years. Impact on development, validation, test In addition to motion control EV requires DC control Need for regulation of the DC/DC converter Necessity for fuel cell (hydrogen, battery, etc.) cycling Demand for E traction motors

5 Agenda Overview Testing Applications Siemens Drives and Motor Solutions Solutions for E-Mobility SINAMICS S120 - Software extensions for test STARTER Demo

6 Common DC Link Application support for test stands Know-how for all kinds of test stand applications SINAMICS S120 Drive Overview Test Stand Applications Control Unit CU320-2 Line Module Motor Modules up to 800 kw Transmission Manual transmission Engine Cold test stand Automatic transmission Hot test stand Differential Transfer case Special Test Stands 3AC V Hz Infeed Motor Braking Module (optional) Hybrid transmission Roller Rigs Brake Drive shaft Balancing machines Absorber Absorber Noise, vibration, harshness (NVH) Performance Tire testing machines Wheel Fatigue

7 Siemens products for test stands SINAMICS S120 Drive System SINAMICS S120 The drive family solution that is fit for the future The SINAMICS drive family offers the optimum drive for each and every drive application all of the drives can be engineered, parameterized, commissioned, and operated in a standard way. SINAMICS Solutions for any drive application Wide range of power ratings from 0.12 kw to 85 MW Available in low-voltage and medium-voltage versions Standard functionality using a common hardware and software platform Standard engineering tools for all drives: SIZER - engineering and selection STARTER - parameterization and commissioning High degree of flexibility and combinability

8 Siemens products for test stands High-performance motors Advantages for test stand applications SIMOTICS M-1PH8 SIMOTICS T-1FW3 SIMOTICS T-1FW6 SIMOTICS L-1FN3 13 Nm Nm rpm rpm 100 Nm Nm 150 rpm rpm 22 Nm Nm 38 rpm 940 rpm 150 N N 105 m/min 836 m/min SIMOTICS segment motor WEISS special motors 100 Nm Nm rpm rpm Nominal speed Nominal torque

9 Testing Equipment Solutions for E-Mobility overview E-Car applications Hybrid or electric powertrain Battery Standard concepts for test stand applications

10 Benefit Solution Task Testing Equipment battery simulation for hybrid Solution with SINAMICS S120 and SINAMICS DCP E-mobility calls for the vehicle inverter to be tested Trend towards higher voltage and voltage constancy without ripple 3AC V Hz SINAMICS S120 Drive Control Unit CU320-2 Infeed Unit up to 1.2 MW ` Motor Modules up to 800 kw SINAMICS DCP 4x DC-DC converter ` DC-link Braking module Integration of battery simulation into the SINAMICS S120 drive system Isolation transformer z. B. 480 VAC : 480 VACs Absorber DC V max. 1,200 A Power controller of the vehicle Energy exchange in DC-Link Compact and economical No additional filters needed Customer specific drive train M Drive motor of the vehicle Transfer gear box of the vehicle

11 Test stands for the e-car drive train Customer profile Market leading test stand manufacturer Project information Customer objectives Siemens solution Test stands to test drive parts of electric cars (motor, transmission & frequency converter) for high performance automotive mfg. Provide DC Voltage to connect the car converter Testing with predefined load profile Minimize infeed power draw With SINAMICS standard components Proven base with SINAMICS S120 drive system 1PH8 motors as absorbers SINAMICS DCP connected to DC link to provide DC source Panel building and engineering by Siemens Customer value Energy exchange within DC link -> low infeed power at main connection point End-to-end solution from AC to DC Panel engineering done by Siemens (e.g. necessary components at output of DCP).

12 Benefit Solution Task Testing Equipment battery and e-motor test Solution with SINAMICS S120 E-mobility requires test of battery systems Trend towards higher voltage for current charge and discharge cycles 3AC V Hz SINAMICS S120 System ` Control Unit CU320-2 Line Module S120 Motor module Integration of the SINAMICS S120 drive system with DCDC CONV tool Isolation Transformer e. g. 480 VAC : 480 VACs Chokes Energy exchange in DC-Link Using standard and proven SINAMCIS S120 components Wide current range 3A-490A DC V, 490A max. Battery Under Test SINAMICS Booksize Capacitor Module

13 Test stands for Battery Test Customer profile Project information Machine supplier for automotive industry Battery test stands for leading automotive mfg. Customer objectives Provide DC Voltage High dynamic DC Source Siemens solution With SINAMICS standard components to success Proven base with SINAMICS S120 drive system SINAMICS motor module with DCDCCONV Customer value Able to use proven Siemens components Siemens components are approved for use at end user

14 SINAMICS S120 software extensions for test stands Technology functions overview Your task Solution with technology integrated in the drive Siemens provides Configurable solution Configurable solution that can be modified as Positioning Simple signal processing (logic tasks) Basic process control Application-specific tasks Application examples of: Drive-related open-loop and closed-loop control tasks Motion control functions Standard function modules: Basic positioner Free function blocks PID technology controller Add on function/ technology modules: Oscillation damping Servo coupling Setpoint input for test stands Control Unit coupling.. Using available signal processing diagrams with SIMATIC S7 control option: Winders, closed-loop tension control... Synchronized axis, flying saws, cross cutters... Standard technology functions Advanced technology functions General drive-related open-loop and closed-loop control tasks Creating graphic signal processing diagrams with a standard library Extensive closed-loop control, arithmetic and logic blocks Customers create/adapt themselves Specific expanded functionality for complex tasks Own function blocks in C/C++ to integrate your own know-how Creating graphic signal processing diagrams with an extended library GMC (synchronous operation, cams, ) Math extension (mathematical functions). Programming your own libraries with an additional development tool

15 SINAMICS S120 software extensions for test stands Advanced technology functions SetPGen Challenge: Easily implement a variable speed/torque set point without advanced programming Set point generator consists of three separate signal generators For generation of sine-wave, saw tooth, square-wave signals up to the 3 rd order harmonic Amplitude, frequency, phase offset and offset can be changed during runtime via BICO Signal frequencies up to 1.6kHz can be achieved (e.g. p0115[0] = 62,5us) Ideal of balancing applications User Benefits Dynamic speed and torque setpoints No programming in drive or PLC environment necessary

16 SINAMICS S120 software extensions for test stands Advanced technology functions POLYGON Challenge: Easily simulate a complex engine torque pulse waveform Torque pulse simulation Mathematical signal generator based on user-defined value table (cam function) Up to 10,000 interpolation points possible Comprehensive dynamic functions: Amplitude, offset, scaling and leading value offset adaptable Output signal Y is dependent on leading value X (e.g. encoder actual value, position, electrical angle) and the parameterized characteristics User Benefits Realistic Test, No fuel consumption Considerable noise reduction Very fast setpoint setting No programming in drive or PLC environment

17 SINAMICS S120 software extensions for test stands Advanced technology functions LECo Challenge: Consistent speed regardless of torque disturbances Learning Error Compensation Automatic disturbance compensation Self-learning compensation Usually learned after 4 6 periods Quality criterion = a constant speed Fault detection over non-periodic disturbing moment -> Speed deviation Ideal for large engine testing Designed for SIMOTION controller User Benefits Few parameter settings necessary Optimal bad engine recognition Fast teaching of new engine types No external measuring technique required

18 SINAMICS S120 software extensions for test stands Advanced technology functions SERVCOUP Challenge: Minimize panel size for high speed/high pulse frequency motors Coupling of several motor modules Coupling of S120 Motor Modules with only one encoder in control mode SERVO Possible for use with linear motor systems Multiple SERVO controllers are digitally coupled within the Control Master-slave coupling on base of torque setpoint realized Proven with high speed Krebs & Aulich motor and Siemens 1FN3 linear motor systems User Benefits Coupling of several motor modules in SERVO control mode possible Increase of current to reach higher torque Splitting the windings of one motor allows use of higher pulse frequencies (using booksize instead of chassis)

19 SINAMICS S120 software extensions for test stands DCC application example Torque Calibration External torque measurement mechanically complex and expensive Torque measuring shafts susceptible to shock and EMC Inverter internal torque measurement inaccurate One-time torque calibration and increase of the internal torque accuracy by means of torque control User Benefits Use of DCB Studio as Siemens high-language programming environment Free downloadable for customers as application example Increase of the internal torque accuracy to approx. 0.1%

20 Selection and engineering tools STARTER commissioning software Commissioning Project can be set up using the electronic rating plates of drive components STARTER offers guided commissioning via Wizards and graphic screens for standard applications Fine tuning is performed via the expert list Includes test and diagnostic functions Usability is continuously enhanced Multi-channel oscilloscope function (Trace) optimizes commissioning, operation and troubleshooting User Benefits Fast controller optimization with integrated oscilloscope Time-savings through guided commissioning Automatic controller settings through frequency response analysis of the complete mechanical axis

21 How did we do? Share your thoughts to win! Got 1 minute? Rate this seminar via MiA App for a chance to win Detroit Tigers tickets:

22 Seminar Slides After MiA, seminar slides will be available at:

23 Questions? James Ellis Siemens Digital Factory Motion Control Strategic Business Development Phone: