We Support the Automotive World to go Electric Inverter and E-Motor Integration and Validation

We Support the Automotive World to go Electric Inverter and E-Motor Integration and Validation 28 June 2018

Automotive drive inverter have complex power interfaces Fuel Cell Booster Cap E-Motor 3 Phase HV Battery E-Motor 3 Phase Picture: Bosch LV Battery DC/DC Conv. Exciter Coil 9

Inverter Design Process Process Phase Picture: Bosch specification fulfilled? production process ok? Engineering Design Design Validation Process Validation 6..10 month 6..10 month Project Launch SOP Start of Production 10

Inverter Design Process Process Phase Picture: Bosch Boundaries: Validation cannot start before design freeze In theory: linear process Practical approach: overlapping areas!!!!!. Risk & Costs Engineering Design Design Validation Process Validation Project Launch Design Freeze 6..10 month 6..10 month SOP Start of Production 11

Inverter Design Process Process Phase Picture: Manageable Bosch Failure Consequences Critical Extrem Engineering Design Design Validation Process Validation 6..10 month 6..10 month Project Launch SOP Start of Production 12

Stop and think Are you coping with the impossible? No! There is a strategy to reduce risk & costs 13

Inverter Validation Process Start the race with a mature design!!! Realistic tests @ earliest possible state Remove the risk of unpredictable issues Find the weak points earliest possible Not influencible! Picture: Bosch Engineering Design Design Validation Process Validation Start Of Project Design Freeze 6..10 month 6..10 month SOP 14

Test labyrinth Inductive loads DC/AC loads Signal- HiL E-Motor & Dyno Don t get lost in the test labyrinth! 15

Test labyrinth No power flow Inductive loads DC/AC loads No realistic test setup No recuperation No dynamics No fault testing No fault testing Don t get lost in the test labyrinth! Power removed Only 5% of electronics in-the-loop Original motor required Dyno controls influences Poor fault testing Models drive models Signal-HiL E-Motor & Dyno 16

The way out of the Labyrinth The way out of the Labyrinth: Inverter test system based on Power-Signal Test Architecture without Mechanics EXIT 17

Start the race with a mature design Inverter Test with E-Motor Emulator (EME): Cutting test time down by more than 90%! Chokes or blocked rotor DC/AC loads E-Motor Testbed 18

Start the race with a mature design Inverter Test with E-Motor Emulator (EME): Cutting test time down by more than 90%! means Performing 10x more tests in the same time frame means 19

More tests means less remaining errors Remaining Errors Detection of errors without EME! Potential risk Engineering Design Design Validation Process Validation Effort / test cases 20

More tests means less remaining errors Remaining Errors Detection of errors without EME Detection of errors with EME reduced risk Engineering Design Design Validation Process Validation Effort / test cases 21

Start the race with a mature design Real motor not required (change motor via mouseclick) Perfect tests of inverter controls (Id/Iq, torque, speed, position) Easy fault injection testing (functional safety ISO26262) no delay, no installation no temperature drift stable operation @ 0rpm infinite fast ramps, high speed electrical & mechanical faults automatable & reproducible Full power lab compatible (road-to-lab) Inverter protection full power next to desk no mechanical hazards adj. phase current limit adj. phase power limit 22

Customer Testimonials: Tier 1 LuK Schaeffler: Torque Vectoring Inverter Test (ASIL-D) correct dynamics! phase short injection active short circuit test short circuit shutdown Further information: ATZelectronic 2015-06 28

Customer Testimonials: Tier 1 The AVL Inverter Testsystem has proven itself as an ideal test tool. Within two weeks we could run a testprogram which used to take half a year! 29

Customer Testimonials: OEM How Mercedes India challenges Silicon Valley AVL Inverter Testsystem "We make sure that new cars drive longer and longer in the virtual world, before we need actual prototypes. That increases the flexibility in development, accelerates the processes and reduces costs on top of that. (Manu Saale, Die Welt, 27.11.2016) "Not for nothing have we set up a testbed in the cellar, which can simulate any electric motor [AVL s Inverter Testsystem], long before it is available at all as a prototype. (Thomas Weber, Die Welt, 27.11.2016) https://www.welt.de/motor/article159733767/wie-indien-dem- Silicon-Valley-den-Rang-ablaeuft.html (27.11.2016) 30

Customer Testimonials: OEM Daimler: Full road-to-lab for complex inverter controls testing E-motor emulator is part of the virtual car Inverter control loop test for smooth traction in office area @ full power! Further information: ATZelectronic 2013-031 31

Your situation? Is your inverter test concept - efficient? - realistic? - fast? 32

Basic P-HiL Based Inverter Test System Battery Emulator 12V Low Voltage UUT-Inverter Bi - Directional Energy - Power Supply Grid Safety Control System Cycle Encoder & Resolver signals E-Motor Emulator 33

Professional P-HiL Based Inverter Test System UUT Table Climatic Chamber Battery Emulator DC/DC Load Automation System 12V Low Voltage UUT-Inverter Bi - Directional Energy - Cycle Power Supply Grid Safety Control System Power Analyzer Coolant Conditioning Encoder & Resolver signals Fault Insertion Rack E-Motor Emulator Tools 34