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E-Mobility

Solutions for E-Mobility Applications



Electric Vehicle/Motor Testing


The Power Analysis module allows measuring every kind of motor (1-12 phase) and inverter (DC-AC, AC-AC, switching frequencies up to some 100 kHz). The modular hardware system allows measuring the power (AC or DC) at multiple points perfectly synchronized. This unique feature allows comprehensive analysis for all types of electric drivetrains (single motor, motor and generator, 2-4x in-wheel-motors) considering also other loads (heating, air-conditioning, 24V, 12V, etc.).


Electric vehicle testing

The high sampling rate and bandwidth of the Dewesoft Power Analyser enable the measurement of wire- less in-wheel motors. And thanks to the small physical size of the hardware, you can even use it to measure the efficiency of electric motorcycles and electric two-wheelers under real driving conditions.


Electric vehicle testing

Hybrid Testing


DEWESoft provides all necessary functionality and analysis for combined power and combustion testing.


Hybrid testing



The Combustion Analysis (CA) module allows detailed analysis of the combustion process. The analysis is perfectly synchronised to the power analysis. The Dewesoft Combustion Analyser enables the user to display and compare measurement data using several different diagrams like, the pV- diagram (pressure of angle) or the CA-Scope (pressure over angle). All CA specific calculations like the mean effective pressure (IMEP, PMEP), heat release, start/end of combustion (SOC, EOC), start/end of injection (SOI, EOI), indicated power, maximum pressure (Pmax), derivate pressure (dp/da) are presented either as colour diagrams or as data tables. For more detailed analysis, statistical calculations per cylinder or over the complete engine can be performed.

Hybrid testing

Additionally DEWESoft® provides a dedicated knocking detection and combustion noise algorithm. The basis for all of these calculations are precise angle position data and cylinder pressure measurement. Dewesoft provides the perfect hardware for this: the galvanically isolated SIRIUSi charge inputs (with up to 24Bit resolution) are in perfect sync to the DEWESoft® super counters. This allows perfect analysis of Hybrid cars already during driving.

Hybrid testing

Hydrogen Testing


The drivetrain of hydrogen cars differs from pure electric vehicles due to the energy storage. While pure electric vehicle use a battery as energy storage, hydrogen powered vehicle use hydrogen as energy storage which is converted to electric power via a fuel cell.


Hydrogen vehicle testing

The drivetrain also includes a so called super capacitor which stores power for short-time peak loads (up to 2000A) and a battery pack. Testing of hydrogen cars affords a couple of AC and DC power measurements (see picture). To determine the efficiency of hydrogen cars, we need additional measurements, like voltage, current and hydrogen flow.


Hydrogen vehicle testing

Battery Testing


The battery as central element in the electrical powertrain strongly affects performance and range of electric vehicles. Extensive tests are necessary: starting from the cell-characteristics up to the complete powertrain. Detailed analysis requires temperature and voltage measurement at multiple points (e.g. 50x cell voltage and 50x cell temperature). The flexible and scalable solution from Dewesoft allows to mea- sure more than 1000 channels from different sensors, perfectly synchronised.


The Dewesoft Power Analyser system can be used for the development of batterys (efficiency analysis, cell charac- terisation, endurance tests, crash tests, short-circuit analysis, overheating / overloading tests, ageing tests, etc. ) as well as for monitoring applications (data logging, transient record- ing, charge-discharge analysis, etc.).

Battery testing

Charging Analysis


Conductive and inductive charging (wireless power transfer).


Charging analysis



Charging analysis can be done for conductive charging (AC or DC) and as well for the increasingly popular inductive charging. The inductive charging process (also called wireless power transfer) affords high switch- ing frequencies of the inverter (up to 150 kHz) to reach maximal efficiency of the power transfer. The high band- width (2 MHz), the high Sampling Rate (1 MS/s) and the possibility to measure AC and DC currents of the Dewesoft Power Analyser fulfils all requirements for testing both, conductive and inductive charging.

Test Bed Application and In-Vehicle Use


The innovative solution of Dewesoft allows measuring the energy consumption of electric vehicles at the test bench as well as inside-the vehicle under real-driving conditions with the same measurement device.


In-Vehicle Use

DS-BP2i battery pack

For the mobile application the measurement device can be powered by hot-swappable battery packs so that measure- ments up to several hours are possible. All sensors (current transducers, GPS, Video) and further equipment like dis- plays can be powered from the measurement device itself

Additionally the zeroflux transducer which need a lot of power (up to 20 watts per unit) can be powered via the additional MCTS power slice.

Testbench

DS-BP2i battery pack

For the application at the test-bench there are several interfaces (CAN, DCOM, etc.) to get data from the testbench control or send data out.

The DEWE-NET option provides remote-control features for the DEWESoft® measurement system, so that you can control the whole test- procedure from a single PC in the control room.







Additional Parameters


The modular hardware design, which offers a wide range of input amplifiers, in combination with the flexible software, makes it possible to acquire a lot of additional data: torque, speed, temperature, pressure, flow rate, video, GPS data (position, acceleration, speed), vehicle bus data (e.g. CAN, OBDII, ...), and many more.

All these additional data sources are synchronised to the Power Analysis signal, even when they use different sampling rates. The unique combination of time-, angle- and frequency-domain data acquisition in one system makes it possible to run multiple analysis functions concurrently: e.g. order tracking, torsional vibration, power and many others.



Highlights

  • Efficiency, Power analysis
  • Test-Bed application and In-Vehicle Use
  • Up to 8 three phase systems
  • Electric Vehicle, Hybrid & Hydrogen testing
  • Battery and Charging analysis

Typical configuration

  • SIRIUS R8D
  • 14x Voltage
  • 17x Current
  • 1x Torque
  • 1x Speed
  • Additional inputs (analogue, digital, counter, GPS, CAN, video, etc.)
SIRIUS R8D





Exemplary E-Mobility (Measurement Results)


ONLINE ANALYSIS OF EFFICIENCY - RECUPERATION - ENERGY BALANCE

Standardised driving cycles (NEFZ, WMTC, etc.) are not suit- able to measure the energy consumption of electric vehicles. They don’t consider all aspects which influence the energy consumption of vehicles and are always done on roller test benches. The future of electric vehicle testing is analysing them under real-life conditions. The innovative solution of Dewesoft allows doing all analysis already during measurement. The sophisticated math functions can calculate different parameters like efficiency, recuperation, etc. and the user-friendly and customisable software interface allows visualisation of all these parameters.The chart shows the exemplary energy flow of an electric vehicle.

Exemplary E-Mobility

Some inverters of electric vehicles (e.g. bus) are working at different switching frequencies to increase the efficiency in different driving situations (city / overland drive). With the Dewesoft Math library it is possible to filter out the currently used switching frequency and automatically do the analysis for different switching frequencies (using logical conditions).

Exemplary E-Mobility

ANALYSING DIFFERENT DRIVING SITUATIONS

There are a lot of parameters which can influence the energy consumption of electric vehicles. These parameters can be ambient parameters like temperature, weather, quality of the road or different driving situations (uphill, downhill, city-, overland- or combined drives) or also different drivers. The Dewesoft Power Analyser makes it possible to do energy analysis considering all of these parameters already during the test drives.

Exemplary E-Mobility

The first chart shows an example of the acceleration behavior of different test drivers on the same test-track (left) and the analysis at different driving situations (right). The acceleration behaviour can influence the energy consumption of up to 10 %.

Exemplary E-Mobility

The second chart shows the acceleration of the scooter at different driving situations. The green chart is the acceleration with full-charged battery, the blue one when the battery was nearly empty, the red one for uphill and the magenta one for downhill driving.

CHARGING PROFILE, CHARGING TIME AND EFFICIENCY

The data logging capability of the Dewesoft Power Analyser allows recording the complete charging process. Example Analysing Charging Profile (red = charging power, orange = energy, violet = power factor):

Exemplary E-Mobility

Charging Part 1: Continuous charging with high power. Within 4 hours 80% of the battery is charged.

Charging Part 2: Reaching of the charging end voltage and short interruption, 86% charged.

Charging Part 3: Last charging part with low power. Within 14 hours battery is fully charged.

EMC TESTS OF CHARGING DEVICES ACCORDING TO IEC61000-3-2 AND IEC 61851

DEWESoft® supports EMC conformity tests of charging devices according to IEC 61000-3-2. The Power Quality Library automatically calculates all necessary parameters.

Instruments like the Harmonic FFT, the Harmonic table, Harmonic reference curve and the scope function ensure fast and reliable analysis.

Harmonic Order Frequency [Hz] Current [A] Current Limit [A]
1 50 1,82 -
3 150 1,42 2,3
5 250 0,95 1,14
7 350 0,58 0,77
9 450 0,45 0,4
11 550 0,44 0,33
13 650 0,36 0,21
15 750 0,22 0,15

Exemplary E-Mobility

Exemplary E-Mobility





Additional Automotive Testing Possibilities


Using the Dewesoft measurement devices allows a couple of another automotive testing possibilities see the list of applications. More details can be found in the Automotive Applications section.


Automotive additional
  • Autonomous Driving
  • Vehicle dynamics
  • Ride and handling tests
  • Brake testing
  • Advanced driver assistance systems
  • Pass by Noise
Automotive additional
  • Road Load Data
  • Performance testing
  • Component testing
  • Modal analysis
  • Structural testing
Automotive additional
  • Combustion analysis
  • Torsional and rotational vibration
  • Order tracking
Automotive additional
  • Crash tests
  • Structural testing
Automotive additional
  • Climate Testing
  • Air-Conditioning Testing
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