Electric Vehicle Motor and Controller Testing
In recent years, pure electric vehicles, hybrid vehicles, and other new energy vehicles have become a trend in the global automotive market. Pure electric vehicles, especially the main route of new energy vehicles, have experienced rapid development in key components such as power batteries, electric motors, and controllers. New energy vehicles exhibit characteristics such as bidirectional working modes, power supply from the power battery, and high power demand. Therefore, the testing methods for electric motors and controllers differ significantly from those of conventional motors.
Xuan'an Technology Power is dedicated to providing testing solutions for the new energy industry. We have designed the HY-LV123 series high-voltage ripple testing power supply specifically for the testing standards of high-voltage components in new energy vehicles, including LV123, VW80303, VW80300, and ISO21498-2. The HY-LV123 series offers a maximum standalone DC output power of 500kW, showcasing significant advantages in testing new energy vehicle electric motors and controllers.
Structure of New Energy Vehicle Systems
In pure electric vehicles, high-voltage direct current is supplied by the power battery, and the controller drives the motor to generate power.
Testing Requirements
Testing standards for electric motors and controllers used in new energy vehicles adhere to the national standard "GB-T18488 Electric Motors and Controllers for Electric Vehicles."
Test Items: General performance, environmental tests, temperature rise tests, motor torque characteristics and efficiency, regenerative energy feedback characteristics, etc.
Main Test Contents: No-load tests, load efficiency tests, maximum operating speed, overspeed tests, motor controller protection tests, locked-rotor tests, motor temperature, temperature rise, overload capacity tests, etc.
Currently, there are two common motor testing systems:
Dynamometer System: The system includes a front-end power supply test DC power source (battery simulator), dynamometer, inverter, and necessary instruments.
Motor Against Load Testing System: The system includes a front-end power supply test DC power source (battery simulator), accompanying motor and its controller, and necessary instruments. The motor controller power supply part in the testing device can adopt a bidirectional DC power source or a DC power source with a DC load.
Xuan'an Technology Power's advantages in new energy vehicle testing solutions are as follows:
The HY-LV123 series high-voltage ripple testing power supply for new energy vehicles possesses high reliability, stability, and conversion efficiency, exhibiting significant advantages in product stability and reliability.
The power supply should have high output accuracy. The HY-LV123 series high-voltage ripple testing power supply achieves a maximum voltage accuracy of 0.05% + 30mV, easily meeting the precision requirements of testing systems.
The power supply output features rapid dynamic response characteristics (instantaneous loading, instantaneous unloading, charge-discharge conversion, etc.). Xuan'an Technology's HY-BP series high-speed power supply for automotive electronic testing has a minimum voltage rise time of less than 1μs, meeting various working condition requirements.
The HY-BP series high-speed power supply for automotive electronic testing possesses bidirectional characteristics, capable of absorbing electrical energy feedback from the motor. It seamlessly switches between bidirectional modes, effectively avoiding voltage or current overshoot.
Schematic Diagram of Motor Against Load Testing System：
HY-LV123 Series High-Voltage Ripple Testing Power Supply for New Energy Vehicles
Maximum Standalone Power: 500kW
Maximum Output Voltage: 1500V
Maximum Output Current: 500A
Maximum Ripple Frequency: 150kHz
The ideal choice for testing new energy vehicle electric motors and controllers.
IV. HY-LV123 Series High-Voltage Ripple Testing Power Supply for VW80300, VW80303, LV123 Test Items.
EHV-08 High Voltage Ripple Generated
Purpose
The purpose of this test is to verify whether the HV component generates HV voltage ripple within the specified limits and whether its HV functional state is unaffected by this self-generated HV ripple.
Test Procedure
Test the ripple content superimposed on DC high-voltage power supply voltage and DC high-voltage power supply current.
Use test setup type 2 as specified in section 4.7.2.
All measurement signals are fed to a spectrum analyzer or oscilloscope with fast Fourier transform (FFT) capability and evaluated.
Determine the worst-case scenarios for each HV operating voltage under possible operating and load conditions before the test. Then, perform the test using this scenario.
Oscillations in voltage ripple caused by low-load conditions, e.g., 5% to 10% of rated load.
Voltage ripple when activating fast control algorithms, e.g., to suppress vibrations caused by mechanical vibrations in the transmission system.
Voltage ripple when starting from stop or low speed to maximum acceleration.
Voltage ripple during low-temperature operation of the heater controlled by duty cycle/PWM.
Conduct tests at the following HV component power levels:
Worst-case scenario determined earlier.
Idle operation of the drive system at 5% to 10% of rated speed.
25%
50%
75%
100%
For each measurement run, generate a spectral amplitude distribution chart for high-voltage voltage and current ripples. In this chart, mark the maximum amplitude and at least the following 10 maxima, with corresponding frequencies and amplitudes, as characteristic frequencies. These characteristic frequencies must be listed in a table, which also specifies all relevant parameters.
If the DUT operates without high-voltage energy storage equipment, run the entire test for this operating condition separately and adjust parameters accordingly.
Requirements
HV voltage and current ripple must remain within the specified limits in Table 31 to maintain functional state A.
Deviation from this requirement applies to functional state B for worst-case scenarios. The functional state does not change due to self-generated ripples from the DUT.
EHV-09 System High Voltage Ripple
Purpose
This test aims to verify the robustness of HV components when subjected to HV voltage ripple generated within the HV system.
Test Procedure
Apply AC voltage with variable amplitude and frequency superimposed on the DC high-voltage power supply voltage of the DUT.
Use and extend test setup type 2 as outlined in Figure 24 and Section 4.7.2. An oscilloscope is used to monitor the injected AC voltage. Test parameters are specified in Table 32.
Test Case 1
In test case 1, the amplitude of the AC voltage superimposed on the DUT is set to the values specified in Table 32 and readjusted as necessary.
It is essential to be aware of resonances between the test apparatus and the DUT during the test. All peaks and troughs of the ripple content in the high-voltage voltage and current in the DUT must be recorded along with their corresponding frequencies.
Test Case 2
In test case 2, the amplitude of the AC voltage superimposed on the DUT is set to the specified 1 kHz value in Table 32. Subsequently, the required frequency range will be operated without changing the injection amplitude. During this process, the amplifier is used only to correct the amplitude-frequency response of the transformer used for injection purposes.
It is essential to be aware of resonances between the test apparatus and the DUT during the test. All peaks and troughs of the ripple content in the high-voltage voltage in the DUT must be recorded along with their corresponding frequencies.
Note 4: If test case 1 shows resonance points at 1 kHz, set the amplitude to a frequency between 500Hz and 1 kHz where there are no resonance points.
Equipment Used:
DPV: Differential probe for high-voltage voltage measurement.
ADC: Data acquisition card.
TR: Coupler.
HY-KP: Broadband power supply.