SAE E-motor Symposium 2012 Advanced Motor and Drive Testing. D & V Electronics Ltd.

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1 SAE E-motor Symposium 2012 Advanced Motor and Drive Testing D & V Electronics Ltd.

2 D&V Electronics Ltd. Company established in 1997 Started as supplier for the aftermarket industry; in few years become #1 supplier of rotating electrical testers for the remanufacturing industry worldwide We had our first major OEM contract in Today we are major supplier of durability, laboratory and production test equipment to Alternator and Starter manufacturers worldwide Started in hybrids 7 years ago; today we supply Electric Powertrain testers for the Electric Vehicle/ Hybrid Vehicle for laboratory, durability and production applications Our customer base is spread in over 90 countries

3 Customers Remy International Valeo Denso Robert Bosch LLC Delphi Ford General Motors Mitsubishi Electric Nissan China 2 nd largest customer for D&V

4 D&V Electronics Ltd. Woodbridge, Ontario Canada

5 Development Process Math Model Prototyping Prototype Testing Validation Testing Application Testing EOL Production Testing On-Field Testing

6 System Level Testing Vehicle Power Management Battery Motor-Inverter Inverter E Motor Controller

7 Some of the Industry Challenges There is no standardization of measuring methods Sharing of information and methodologies Performance is affected from other components in the system There are not many manufacturers producing the complete system; as result components availability is limited Developments are very dynamic Some direct measurements are hard to perform

8 Our Approach More than just a systems integrator We are developing our own solutions to meet the emerging market demands We bring 15 years of electrical testing expertise to view the problem clearly D&V builds the system in a modular fashion without compromising a integrated interface and applications In this leading edge technology we are customer focused to bring them forward in this technology We see it as a partnership between us and the customer because as they grow and do well the market will develop further and we will grow with them If there is no product that the customer needs we have the expertise to develop it and build it We try our best to support the entire development process including performance, reliability/endurance, and production testing

9 Typical Tester Block Diagram AC REGEN ~ = Battery Simulator Battery Load Motor Torque E Motor S A F E T Y Instrumentation and Control Position Feedback Resolver Emulator

10 Measurements Standard measurements torque, speed, voltage current etc. Temperature, coolant temperature, flow, calorimetric losses NVH, including sound, vibration, torsional vibration etc. LRC and HV measurements Resolver characterization Inverter characterization Inline and reaction torque In case of BAS style systems we perform torque measurements before and after the belt drive Calculated parameters

11 Testing Variety of performance testing Peak performance, less than nominal performance etc. BEMF and stall test Efficiency mapping Control angle sweep Temperature mapping Motor model parameterization (like D,Q inductance, leakage inductance, material losses, inertia etc.) Order tracking and spectrum analysis for vibration and sound in 6 channels Cogging torque, friction losses, torsional vibration Design validation tests Endurance testing, HALT etc. Go-No Go and performance testing for EOL applications Inverter performance and operation test System level testing Transformation ratio, positioning device accuracy Other calculated parameters

12 Solutions: Battery Simulator High power bi-directional battery simulator Variable voltage 20V to 1000V DC and scalable output power by paralleling (up to 3200 Amps) Programmable voltage, current and impedance. Fully integrated into electrical powertrain test stands for laboratory testing applications Ability to regen into the grid Very high switching speed Amps/msec. 25 mv typical error at 500 Volts

13 Our Solutions: Dyno System Drivetrains from 15kW to over 600kW Torque 50Nm to over 4,000Nm peak Speed up to 20,000 rpm and above Thermal Chamber options Temperature measurements for Motor/Generators D&V Inverters and Power Analyzers

14 Our Solutions: Resolver Testing Resolver testing Develop number of resolver testers and emulators Expand inverter capabilities to operate with different motors Focus on testing of transformation ratio and resolver error

15 Our Solutions: Inverter Testing Testing of inverter in simulated vehicle environment Efficiency, thermal losses and algorithm verification Testing with high level input interference IGBT stress test and device aging

16 Other System Components Custom Inverter Design Power Meters and Analyzers Oil and Water Conditioning Systems Regen Load Bank PMM-3 BSS-20 LCS-108

17 EPT HV/EV Electric Motor & Controller Test Systems EPT-350 EPT-120 Hybrid & Electric Vehicle Electrical Systems Motors / Generators Drives / Controllers / Inverters Start / Stop Systems EPT-100

18 BST-240 Battery Tester

19 Durability Testing of Inverter Tests Dual motors and oil pump EPT-350

20 Emulates Complete Vehicle EPT-350

21 EPT-120 Durability Testing 1,000 V 800 A Rollaway Thermal Chamber Dual Load Motors 1200Nm 6000 rpm 11,000 rpm 500Nm

22 EPT 100 Production tests motor, stator, rotor with customer inverter or D&V Inverter

23 Semi - Automatic Tooling EPT-100

24 EPT-130 Start-Stop System

25 ST-69

26 ST-69

27 ALT-72

28 World Leading Technology ST Tester Engine Simulators Production Testers

29 testing the future D&V Electronics Ltd. Thank you

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