E-MOBILITY TESTING ALONG THE V-CYCLE EMPHASIS ON THE INTEGRATION TESTBENCH. Markus Maier, RBM Germany

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1 E-MOBILITY TESTING ALONG THE V-CYCLE EMPHASIS ON THE INTEGRATION TESTBENCH Markus Maier, RBM Germany

2 AGENDA Overview AVL Testing Solutions Electrification for Subsystem Electrification Summary Markus Maier, RBM 06 November

3 ELECTRIFICATION OF THE POWERTRAIN Voltage el. Power el. Distance Hybrid Technology Micro Micro / Mild Mild Full / Plug-In BEV / FC 12V 0,5..3 kw 0 km 1 12V / 48V 3..8 kw 0 km 2 48V.. 130V kw ~2 km 130V.. 400V > 20 kw > 20 km V.. 800V > 75 kw > 150 km Higher CO 2 Benefit vs. increasing System-Complexity and System-Cost 1 Stop-Start Systems largely introduced. 2 48V Based systems promise best ratio between cost, features and safety 3 Plug-In Hybrids very attractive for CO2 Super-Credits 4 Technology is key for pure electric driving ( Electric) market for pure electric vehicles to develop along new mobility concepts Markus Maier, RBM 06 November

4 Clutch Gearbox Belt AVL Test -Solution AVL SOLUTIONS ELECTRIFICATION V-CYCLE Upgrade existing es On-Road Validation in In-Lab Generator + - Inverter Validation on Powertrain ICE Motor Sub-Systems Validation at Component test / Emulation E-Motor Test Starter-Test Powerelectronics Testing Components Markus Maier, RBM 06 November

5 Topology TESTING OF COMPONENTS Inverter HV/48V 12V e-motor ISG/RSG HV/48V DC/DC Converter HV/48V Sink 12V 12V Sink AVL Test Solution Component Test Testing of electrical sinks by emulating the battery or Super- Caps by emulating the sinks Dynamometer E-Motor Emulation Automation-System (AVL Puma, AVL Lynx) DC-Source/Sink -Emulator Markus Maier, RBM 06 November

6 AGENDA Overview AVL Testing Solutions Electrification for Subsystem Electrification Summary Markus Maier, RBM 06 November

7 Clutch Gearbox Belt ELECTRIFIED POWERTRAINS TESTING Electrified Powertrains - Characteristics High number of operating modes (recuperation, boost, sailing, etc.) Integration of components from different Tier-1 New, partially unknown technology High number of interfaces to the vehicle (external loads) Today: Whole Powertrain Inverter + - Generator Motor ICE System Integration Test - Today Integration with Combustion Engine and Gearbox to full Powertrain and Testing on Powertrain or in the Challenges one Component can block the whole testing Debugging of faulty systems compex while in the car Tomorrow: Subsystem Electrification Inverter AVL Solution Integration for Electrification Subsystem Motor Markus Maier, RBM 06 November

8 AVL Test -Solution AVL SOLUTIONS ELECTRIFICATION V-CYCLE Upgrade existing es On-Road Validation in In-Lab Validation on Powertrain Sub-Systems Validation on E-System Validation at Component System-Prüfstand + - Inverter Motor test / Emulation E-Motor Test Starter-Test Powerelectronics Testing Components Markus Maier, RBM 06 November

9 HIGHLIGHTS AND POSSIBILITIES Realistic Simulation of Driving Cycles with different Start conditions NEFZ Cycle with different charging status of the battery Different Possibilities to inject Faults / Errors Network: Failure of single ECUs / Components E-Motor: cut single phase Grid Supply: Phase failure, asymmetric phases, Peaks Bordnet: Voltage Drops caused from dynamic loads HV-Bordnet: Isolation fault, cable breaks Excellent Comparison between Emulation and especially in dynamic load scenarios High Performance Testing Dynamic switching between emulated and real component allows different use-cases to be tested e.g. driver selection switch for operating modes Markus Maier, RBM 06 November

10 SUMMARY AVL Electrification Testing along the V-Cycle Solutions fro Component Testing to Subsystem Testing to Validation Fully integrated and smoothly co-working On-Road Validation in In-Lab Markus Maier Business Manager Electrification & Racing Instrumentation & Test Systems Tel.: Mob.: Sub-Systems Validation at Component Validation on Powertrain Validation E-System Components Markus Maier, RBM 06 November