Varroc Engineering

The Customer was needing testing systems that would enable the mapping of performance parameters of their EV traction motors, types: (1) Hybrid Synchronous AC and Asynchronous AC Induction motors; (2) Synchronous BLDC and PMSM; and (3) ISG motors.

In addition, the systems could also (4) test the EV Traction Motor integrated with gearbox, i.e. having two O/P’s (similar to a Transaxle); and (5) are suitable for evaluating Hub Motors.

The systems were designed for evaluating motors of multiple types and of multiple manufacturers, with ranges of up to 25 kW, of up to 80 V, and max speeds of up to 15000 rpm.

The systems included Battery Simulation, with battery cycle testing (charge/discharge), battery SOC (State Of Charge) script and battery SOD (State Of Discharge) script, during advanced battery simulation and simple battery simulation, drive cycle testing (real-time simulation of scooter/driver, with acceleration, brake, change of vehicle states); and Battery Testing.

All advanced requested Motors Under Test are driven by their respective controller, with different types of communication protocols (CAN, LIN, A/D, FlexRay, Speedgoat, Modbus, etc.)

About the Product:

Varroc’s system includes the capabilities for testing electric motors listed below.

MAIN CAPABILITIES

The testing solutions Motomea supplied are Regenerative Dynamometer Systems (RDS).

Complete Load performance testing:
- Torque, Speed, Current, Efficiency, Power Input, Power Output.
Automatic Temperature rise testing:
- 4 to 16 channels for thermocouple.
- Temperature readings are synchronized with Current, Voltage, Speed, Torque, Power Input, Power Output.
- S1 to S8 IEC duty cycles.
Electrical Vehicle Motor Drive Cycle Load Simulation: Real-time simulation of scooter/driver, with acceleration, brake, change of vehicle states.
Load from Excel – Load according to predefined Table or Formula.
Bidirectional power supply of up to 1000 V / 1000 A.
Battery Simulation (simple and advanced batteries):
- Cycle testing (Charge/Discharge).
- SOC (State Of Charge) script.
- SOD (State Of Discharge) script.
- Special feature: Low voltage dip at current transient.
- System includes Output Filter with high capacitance.
- U mode: Voltage Control (CV).
Unique Battery Testing (simple and advanced batteries):
- SOC (State Of Charge) script.
- SOD (State Of Discharge) script.
- I+ mode: Current Control (CC+).
- I- mode: Current Control (CC-).
- P mode: Power Control (CP), CC-CV.
- Step for cut-off condition (ET, EV, EC, CC time, CV time, Cap%, etc.)
- Protection (OV & LV, OC & LC, OT).
Generator Testing – ISG.
Standard electrical parameters testing:
- HV, Vibration, Noise, and others.
Additional testing:
- Cogging, Back EMF, Friction, Friction Spectrum, Ripple Torque.
Additional EV tests:
- Performance Generating & Performance Motoring modes.
- Stall Torque, Cogging Torque.
- Back EMF RMS, Open Circuit Back EMF, Back EMF Constant K_E.
- No Load Coupled & Uncoupled.
- Torque Ripple Measurements at Low RPM & at High RPM.
- Electromechanical Time Constant.
- Voltage and Current Harmonics.
- Load from Excel File.
- Speed Torque Scope Viewer.
- Deceleration Test (MOI Calculation).
- Servo Bandwidth (Speed Loop & Current Loop).
- Dynamic Testing during acceleration and deceleration.
- Friction vs. Speed, Friction Drag Torque.
- Torque Speed FFT.
- Performance at Variable Voltage.
- Inductance Test 3 Phases.
- Vibration.
- ISG Tests: Generation Characteristic.
- ISO Efficiency Tests: ISO Efficiency and ISO Efficiency Contour.
MUT can be controlled via CAN, PWM, analog, and other types of communication protocols.

Varroc Engineering

About the Product:

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