Vehicle Powertrain Dynamometer Tender Documentation 1
Contents Description of the dynamometer... 3 Summary... 3 motors specification of the dynamometer for differentials... 4 Technical specification power drive systems... 4 Input A-C motor... 5 Output A-C motors... 5 Technical specification Motor Control... 6 Test 1 condition:... 6 Expected results:... 6 Test 2 conditions:... 7 Expected result:... 7 Test chamber... 7 Test chamber operation and data collection assurance... 7 Test chamber data acquisition system, I/O channels and HW definitions... 8 Test chamber control system... 10 Test automation support system... 12 Test cell monitoring and operator workplace... 12 Connection between a motor and the torque sensor assembly (Spindle assembly)... 13 Interface cabinets... 13 Bedplate... 13 Torque sensor... 14 For output motors... 14 For input motor... 14 Adjustment of a position of the motors... 15 Mechanical lock system of the output motors... 15 Covers of the rotating parts... 15 Heat exchanger for oil of a testing sample (differential)... 16 Attachement... 16 2
Description of the dynamometer A testing dynamometer is a device used for measurement of output quantities of an investigated component. There are many types of dynamometers for measurement of different parts of a powertrain (engines, transmissions, differentials, etc.). For our purposes, for measurement of differentials, there is the assembly of the input motor, so called Primer mover, which delivers all the desired input quantities into a testing sample and two output motors, so called Absorbers, needed for measurement of the output quantities and for transformation the power to further usable electrical energy. The Prime mover, representing a drive unit of a vehicle, simply allows to simulate any driving mode. The Absorber, representing a wheel of a vehicle, allows by a reaction torque and speed to simulate any situation between a roadway and a wheel of a vehicle (for example wet/dry asphalt, wet/dry concrete, etc.). The Absorber consists of a generator transferring the output quantities to electrical energy which is usually further used and so not all the input power is dissipated. Figure 1 is an illustrative layout of the dynamometer. Figure 1 Summary This document was created to provide the technical specification of the dynamometer and its additional devices for potential suppliers. There are two equal tender documentations (in Czech and English language). The authoritative documentation is in English language. It is necessary to take into account the dynamometer has to meet all the legislative requirements which will be valid at the time of the commissioning and will be align with all necessary automotive standards and requirements. It is also necessary that complete testing equipment meets all Eaton safety standards and will be integrated to safety system of complete building. 3
Actual speed EATON EUROPEAN INNOVATON CENTER EEIC motors specification of the dynamometer for differentials Technical specification power drive systems The dynamometer has to have a Power Drive System for each of the tree propelled axles. Each of the power drive systems has to contain an electric motor equipped with an angular speed sensor and a variable frequency inverter that drives the electric motor. Each of the motor shall be equipped with an electromechanical brake with a mechanical unlock possibility and electrical control connection and power supply. So all of the used electric motors must be ready to be controlled by variable frequency drives. The whole power system can be equipped with one AC three phase input with an input rectifier or an active front end in order to assure stable and controlled DC bus voltage system. And each of the Power Drive Systems for driving motors has to be powered by this DC bus system (Figure 2). Alternatively three standalone variable frequency drives for the motors supplied individually from a three phase AC system (equipped with an input rectifier) have to be interconnected between each other through a single DC Bus system in other to be able to transfer braking energy (Figure 3). The system has to assure constant, stable and controlled DC bus voltage. The recuperation of the electrical energy (Enclosed in the DC bus system, not to the electrical grid) is wanted to reduce heat produced by the dynamometer. In all the possible cases, the power has to be recovered for the propelling purposes. In addition all the drives has to be equipped with a breaking chopper and a braking resistor and if the DC bus cannot handle the energy (it is not used by another frequency inverter for driving the motor) the braking resistor has to assure proper braking time for the motor. Dissipating the power on the breaking resistor has to be executed only in case that the energy cannot be used for driving purposes. Every grid connected to drive has to have mains chokes (mains filter) and each of the power drive has to have motor chokes. Drive Actual speed M DUT Actual speed M Drive Breaking resistor BR DC- Motor Motor BR DC- Breaking resistor M Motor Drive Breaking resistor DC- BR Rectifier / Active Front End AC/DC converter 3x400VAC Main chokes DC- Figure 2 4
Actual speed EATON EUROPEAN INNOVATON CENTER EEIC 3x400VAC Main chokes Drive DC- Actual speed M Motor DUT Actual speed M Motor Drive DC- Main chokes 3x400VAC M Motor Drive DC- DC- Main chokes 3x400VAC Figure 3 Values at the tables below are the minimal for the motors of the dynamometer. Input A-C motor Revolutions (Rev/min) Power (HP) Power (kw) Torque (LB-FT) Base Speed 1473 400 298 1426 1933 Max. Speed 4999 400 298 420 569 Min. Speed 0 0 0 1426 1933 -air-cooled (forced ventilation) (DE -> NDE direction) Torque (Nm) Output A-C motors Revolutions (Rev/min) Power (HP) Power (kw) Torque (LB-FT) Base Speed 650 371 277 3001 4069 Max. Speed 2400 371 277 812 1101 Min. Speed 0 0 0 3001 4069 -air-cooled (forced ventilation) (DE -> NDE direction) Torque (Nm) 5
Technical specification Motor Control Each of the power drive systems (Variable frequency inverter and electric motor with a speed sensor) has to assure high performance acceleration and dynamics. All power drive systems have to comply in minimum these basic requirements. The drive system has to assure 100% of motor torque at steady 0RPM of electric motor speed. The drive system has to assure 150% of overload of electric motor for 60 seconds. The drive system has to assure 200% electric motor overload for min 4 seconds. The drive system has to assure the motor acceleration from 0 speed to nominal (base) speed and also the deceleration from base to 0 speed in the maximal possible physical rate, the rotor of electric motors has to be less than 1,8 kg m 2 for the 1473RPM motor and less than 8 kg m 2 for the 650RPM motors. All the power drive systems have to comply the two basic tests: Test 1 condition: Two electric motors connected shaft to shaft (Figure 4). There is a torque sensor between the two motors sampled at 1kHz One motor in torque control, the other in speed control regime. Both motors are running at twice the nominal (base) speed (200% base speed). The torque control motor is set for 5% torque. The motor that is in speed control is requested to go to opposite direction down to 120% base speed at a rate such that full motor current is required. Basically the output motors are connected by a sufficient stiff shaft and the input motor is not involved at all. Figure 4 Expected results: The torque read by the torque meter never varies from the 5% + inertial induced torque by more than 5% of rated torque (This includes motor torque ripple). 6
Test 2 conditions: To prove the accuracy of speed control a full load torque is applied at constant speed. One motor in speed control at 25RPM. A high rate speed sensor. Brake attached to motor shaft is applied to load the motor from 0% torque to 100% motor torque in 20ms. 3 seconds later, it releases in less than 20ms. This test should be executed on all the motors to prove the accuracy, see at the Figure 5. There has to be designed a mechanism (a simple gear plus a control clutch) for the connection of the prime mover and an absorber. Figure 5 Expected result: Speed of the motor stays at 25RPM ± 4RPM. Both of the tests have to meet repeatability requirement. To get ten times the same results +/-1% of deviation. Test chamber Test chamber operation and data collection assurance The test chamber is referred as the space where the Differential test stand, its electronic control system and the operator workplace are placed. Test cell contains the main electric, electronic and mechanical test equipment and is physically isolated from the Operator Workplace There can be several cell access points (doors) to the test cell. The chamber control system has to secure the access to the cell through controlling the door electromechanical locking system. The test cell shall not be access unless the inside of the test cell is in a safety state (components have zero energy). The Test Chamber has to be equipped with computer hardware that will be able to assure the requirements for safe and reliable test cell operation, data collection, and test automation. This hardware should be composed of analogue and digital input and output cards for signal data collection and one or more real-time PCs (RTPC) alternatively a platform with Multi-Core/Multi-CPU with the ability to acquire, process, store data and run critical drivers and the control logic in a deterministic real-time environment, where the user interface shall be physically separated from the 7
control processes. The user interface application shall reside in the Operator PC. The Operator PC shall include the use of an IT-approved standard PC compatible with the building IT infrastructure. The Operator PC shall be situated outside the test cell. The test cell control system shall be backed up by an UPS. All the systems HW shall be placed in an Operator Console Rack Enclosure inside the Operator Workplace. The communication details and definitions between the IO modules, the RTPC and Operator PC have to be open (protocol shall be open) or the detailed specification shall be provided. Control system has to be equipped with an emergency circuit with emergency buttons that shall be easily accessible by the operator which activation shall deactivate the test and bring all the components inside the cell into a safe state and shall have priority over a stop for operational reasons or any start functions and is maintained until the system is reset. Interruption of incoming power to the test system, either from power failure or disruption from a safety interlock, shall not result in a hazardous condition. The test equipment shall not spontaneously start when power is applied or returned. A reset function on the safety control circuit could be used to eliminate spontaneous starting. The Operator PC application shall be implemented as a large scale commercial dyno control software package where the entire test chamber shall be managed from. This has to provide a user access to test operation control, visualization and HW terminal. An application shall be provided for basic and advanced test cell operation and data processing, visualizing and data collection. All the used hardware shall not be proprietary otherwise all the hardware and software detailed definitions shall be provided. The typical test applications will include certification and R&D tests running transient test schedules with different parameters and varying environment conditions and tests involving simulations. Test chamber data acquisition system, I/O channels and HW definitions The data acquisition system has to be compatible with the CANape software/hardware (Vector company). The test cell shall be equipped with an inside placed electric connector panels that shall contain more electrical connectors for assuring the connection of all in this document requested signals to the outside of the test cell. All the requested signals has to be wired from the cell interface panel to the test control HW. A connection of a testing sample with the data acquisition system of the dynamometer must be allowed from the testing point of view. Additional signals can be installed from the DUT and the connectors and wires to the test control HW shall be assured. A testing sample can consist of some integrated sensors (temperature, pressure, etc.). For these reasons, there shall be several additional cables with connectors at their end wired between the cell interface panel and the test control HW. There must be at least 15 such additional cables with the connectors. 8
The I/O system shall provide synchronized data acquisition in a distributed test environment at high data sampling rates. All the modules have to be based on Non-proprietary hardware. The system shall be easily expanded or scaled down, making unused I/O modules available for other parts of the test cell. This creates a laboratory environment where each test cell is equipped with an optimal set of I/O. Modules addressing specific needs can be added as needed. The minimum requirements for the I/O modules Real time distributed RS422 IO system Sixteen (16) Analog Inputs for Transducers Sixteen (16) Analog Inputs for RTDs Sixteen (16) K-Type Thermocouple Channels Four (4) Analog Outputs (Module sample rates at least 100Hz with the resolution 16bit) Twelve (12) Frequency Inputs Eight (8) Analog Inputs (Acquisition Rates for the fast analogue inputs shall be not less than 20kHz with the resolution of 24 bits) Sixteen (16) Digital Output Channels with SPDT 24VDC 10A Relays Sixteen (16) Digital Inputs (Module sample rates at least 100Hz with the resolution 16bit) Galvanic Isolation up to 1200 V for each channel, supply and interface Low susceptibility to electromagnetic interferences Operating temperature in the range of -20 to +60 C Full configurable by user (Hardware/Software) Integrated real time channel limit monitoring It shall be possible to integrate any additional HW I/O module afterwards. The architecture shall be opened also to third parties I/O systems. For the basic I/O module synchronization a data concentrator shall be available to synchronize data capture and for adding time stamps into the data. Basic system architecture includes an Industrial Ethernet connection too. A typical configuration may look like (Figure 6): 9
Figure 6 Additional hardware and drivers required are: The CANbus RealTime is a real-time driver with a base communication interface and the PCI CAN interface card. The driver shall supports 2 High Speed CAN busses per/board and up to 4 boards (8 busses total). The HW shall be equipped with standard communication ports for serial communication ports and several Ethernet (TCP/IP) on RTP ports. Test chamber control system The test chamber has to be equipped with hardware and adequate software to assure controlled and safe operation of all the electric, electronic, and mechanical parts and environment of the dynamometer. The control system has to be compatible with itest (A&D technology company) test definitions and configurations. The following primary functionality shall be assured: Chamber control, persons access control, instrumentation checkout, test cell initialization, proper startup and shut down of tests. Automated execution of tests. Maximum and minimum limit control for all the predefined variables, emergency shutdown assurance and signalization. 10
The following signals have to be acquired, monitored and optionally stored and displayed from the test cell: Torque values from all the three axels of the differential. (see torque sensor definition) Speed values from all the three axels of the differential. (see torque sensor definition) Temperature of every individual electric motor and its electric drive system (these signals can be measured inside the drive system and send via a digital bus to the main controller PC) Temperature inside the test cell (temperature distribution and appropriate number of sensors TBD) All faults evaluated by the drive have to be signaled to the control system Actual power and energy consumption information has to be sent to the control system Additional analogue and digital inputs and outputs has to be prepared for future potential new signals Emergency circuit activation has to be signaled to the control system and chamber management system In case of Emergency, the control system has to assure the default (safe state) settings for all controlled channels The controlled channels shall provide the capability to manually control at minimum following actors: Individually all the frequency inverters (enable signals) Individually speed of all of the electric motors Individually the torque of all of the electric motors Individually all the electro-mechanic brakes Door locking system A part of the control system application has to be a monitor that checks limits and performs a safe shutdown if any of the limits is exceeded. This monitor has to be configurable in terms of the amount of evaluated variables and their limits. The control SW application has to be provided separately and with all the adequate documentation including the description of interfaces. A high performance modular system shall include a powerful scripting engine and API for complete customization. It has to be compatible with third-party systems, using either a provided library of device drivers or enabling the development of a customized driver. The main control application shall be composed of few parts. Test management environment that shall be a fully functional development environment for creating and editing test schedules and test and test configurations, defining PID loops and other parameters. As the next an operator GUI shall be provided that will contain interactive displays and manual controls that will enable runtime editing of screens and running automated test schedules. The creation of GUIs shall be customizable. Few of the minimum HW requirement contain. Visual interactive displays that can be edited on-line (during runtime) Manual controls to command the connected equipment Interface for operator messages and data visualization Charting live data 11
Control of data logging Selection and control of automated tests Display of test end reports Quickly build and edit user displays from configurable panels Create and edit test schedules Define test and equipment configurations Configure I/O channels PID loop definitions and tuning System limits, limit groups, and actions Data logging definition Instrument definition Test cycles Full support for scripting editor (VCL) with debugger Automated Transient Test Sequencing capability Vehicle simulation capability Minimum real time calculation and control rate of 500Hz Multiple test flow options Minimum of 5,000 user defined channels Independent filtering, signal conditioning and processing, and math functionality on every channel Minimum of 1,000 simultaneous calculations Minimum of 20 PID groups Minimum of 6 active PID at 500hz Driver support for CAN, XCP, CCP, ASAP3, ASAM MCD3, CANApe API, FieldIO, Driver support for EtherCAT I/O device Driver - RealTime Python with interpreter Test automation support system A model based platform solution shall be available for vehicle and test cell simulation and test control. This platform shall be used for model-based (simulation-based) control in hardware-in-the-loop and differential-in-the-loop testing applications. A Simulation software package shall be provided with all the necessary blocks to access all the peripherals of the control system. All the necessary documentation has to be provided. In addition, control of the system shall be able to be passed to other host platform software, such as the control, data acquisition and test management application. Test cell monitoring and operator workplace There must be available 4 screens within the control room. Each of them has an option to display an arbitrary systems of the dynamometer. 12
Connection between a motor and the torque sensor assembly (Spindle assembly) This connection has to be designed with respect to the diameter of the shaft and the dimensions of the keyway of the motors. The wanted solution are bellows couplings with proper torque limits. The torque requirement for the output motors is 10000Nm and for the input motor is 6000Nm. Spindle assembly is connected with the motor and with the torque sensor according the Figure 7. Figure 7 Interface cabinets The requirement is to have the electrical interface cabinet twice bigger than it is necessary (for future upgrade). At least 6 additional 230V 50Hz power outlets has to be provided two with 16 and two with 32A circuit breaker protected. Bedplate The motors of the dynamometer have to be located on a suitable damped bedplate and bolted to the T-grooves of the bedplate. But their movement has to be allowed for an adjustment of their position (see at the chapter: The adjustment of a position of the motors). The room of the dynamometer is located at -1 floor and there are other rooms of the building below that. For this reason, all the changes to the floor have to be discussed and approved by the building facility manager. The preferred conception is a suitable air-based (pneumatic system) bedplate, which maximally minimizes vibrations from the dynamometer, with minimal changes into the concrete floor of the room. The pneumatic system is automatically controlled to prevent vibrations to transfer to the floor. The floor load limit is 1500kg/m 2. The dimensions of the doors from the garage have to be taken into account, to get all the equipment in the room. 13
Torque sensor For output motors >5kNm rated torque >700Nm bending moment >11kN lateral force Accuracy values based on frequency output of transducer. 0.05% accuracy grade Max nonlinearity from 0 to 1000Nm 0.01% Zero drift with temperature per 10degC 0.05% Span shift with temperature per 10C 0.05% Frequency range of at least 4kHz (-3dB) Long term drift <0.03% Analog torque output Encoder output for speed 1024 ppr Frequency output for torque Torsional Stiffness > 5000 knm/rad For input motor >3kNm rated torque >500Nm bending moment >9kN lateral force Accuracy values based on frequency output of transducer. 0.05% accuracy grade Max nonlinearity from 0 to 1000Nm 0.01% Zero drift with temperature per 10degC 0.05% Span shift with temperature per 10C 0.05% Frequency range of at least 4kHz (-3dB) Long term drift <0.03% Analog torque output Encoder output for speed 1024 ppr Frequency output for torque Torsional Stiffness > 3000 knm/rad 14
Adjustment of a position of the motors The adjustment of a position of the motors has to be designed to easily allow a desired distance between the motors. Each position has to be firmly fastened to prevent a movement (bolted to the bedplate, tightened by nuts, etc.). The axial force acts towards a motor could be up to 40 000N so there has to be a proper fastening system to prevent any movements of the motors. The adjustment of all the motors has to be according to the Figure 8. The position of the prime mover (the input motor) has to be allowed to adjust even in the z-direction (the direction of floor-ceiling). The normal position is in one plain (the axial axes are in the same plain) and the prime mover is allowed to adjust by +150 mm in the z-direction (direction up). Figure 8 Mechanical lock system of the output motors There has to be an mechanical lock system to prevent shaft movement. Both of output motor shafts have to include this lock system. This requirement is needed from the testing point of view. Covers of the rotating parts All the rotating parts have to be secured from safety point of view by a suitable metal covers. The covers have to be bolted by T-groove to the bedplate. The installation has to be allowed after the adjustment of the whole testing sample (as the last step before the start of a test). One of a suitable conception is at the Figure 9. 15
Figure 9 Heat exchanger for oil of a testing sample (differential) It is necessary to keep a desired temperature of the oil of a differential from the testing point of view. A temperature of the oil, circulating from the heat exchanger to a differential, has to be adjustable for the range of +20 C to +150 C with tolerances ±2 C. There is a possibility to use the central water distribution within the room for cooling down the oil of a differential. The temperature of the central water distribution is between +10 C to +45 C. The power of this heat exchanger has to be at least 9 kw. The temperature in front of the entrance to the sample muss be guarantee to be at a desired value (heat loses in the connection - hoses). There must be a proper filter at the oil loop to catch small steel chips. The flow rate of the oil has to be controlled and observable from the operator workplace. The flow rate has to be adjustable from 4l/min up to 90l/min. The system should contain of at least 20 liters of the oil. It is necessary to heat up the oil in such a way so the oil does not degrade (a local temperature must not exceed a certain level). Attachement No. Name of the File Description Type of the Document 1 Dyno-room.stp 3D model of the room for the dynamometer 3D step model 2 Layout.jpg Layout of the dynamometer + description Figure Dyno-room.stp is 3D model of the room for the dynamometer. There are modeled all the parts of the room + the desired layout of the dynamometer, drives and the heat chamber (not part of this tender documentation). There are also depicted the pipes of the fire-extinguishing and the ventilation system. There are described the whole layout of the room and the dynamometer at Layout.jpg. 16