AVL ELECTRIFICATION TEST SOLUTIONS

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1 AVL ELECTRIFICATION TEST SOLUTIONS E-INTEGRATION TEST SYSTEM Mario Propst AVL List GmbH (Headquarters)

2 CONTENT o Applications o System solutions o Product solutions o Use cases o Customer References Mario Propst 16 Mai

3 INCREASED SYSTEM TEST COMPLEXITY WITH E-COMPONENTS Complete Vehicle On-Road In-Lab Validation In Vehicle Electrification Subsystem is complex Sub-System Close the gap with E-Integration testbed Validation in powertrain testbed Validation in component testbed Components Mario Propst 16 Mai

4 CONTENT o Applications o System solutions o Product solutions o Use cases o Customer References Mario Propst 16 Mai

5 SOLUTION > E-INTEGRATION TEST SYSTEM AVL E-Integration test system: Complete Vehicle Close the gap between component verification and product validation Sub-System On-Road In-Lab Validation In Vehicle Validation in powertrain testbed Validation Easy Efficient Safe Components Validation in component testbed Mario Propst 16 Mai

6 AVL E-INTEGRATION TEST SYSTEM TYPE E-DRIVE AVL E-Motor Emulator AVL Universal Inverter AVL Measurement Trolley Environmental Chamber Battery AVL Load System Inverter Table E-Motor Mario Propst 16 Mai

7 Emulated World Real World E-INTEGRATION TEST SYSTEM - REAL WORLD Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

8 Emulated World Real World E-INTEGRATION TEST SYSTEM - EMULATED WORLD Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

9 Emulated World Real World E-INTEGRATION TEST SYSTEM - OVERVIEW OF ALL COMPONENTS Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

10 Emulated World Real World SYSTEM TESTING Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

11 Emulated World Real World SYSTEM TESTING WITH EMULATED BATTERY Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

12 Emulated World Real World SYSTEM TESTING WITH EMULATED INVERTER Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

13 Emulated World Real World SYSTEM TESTING WITH EMULATED E-MOTOR Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

14 Emulated World Real World COMPONENT TESTING - BATTERY Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

15 Emulated World Real World COMPONENT TESTING ONBOARD CHARGER Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

16 Emulated World Real World COMPONENT TESTING INVERTER Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

17 Emulated World Real World COMPONENT TESTING E-MOTOR Clamps (15, 30, etc.) and bus communication (CAN, Flexray, etc.) External controllers UUT Battery UUT OBC UUT-Inverter E-Motor Load Unit Drive Shaft BCU (BMS) Gearbox, E-Motor, Battery controller, etc. HV DC link 3xAC Mains 3xAC e-motor Configuration Switch Unit Signal & Restbus Switch box Battery Emulator/Tester Mains Emulator Universal Inverter e-motor Emulator Automation Mario Propst 16 Mai

TYPES OF E-INTEGRATION TEST SYSTEMS TYPE 1 - PRE INTEGRATION Puma controls all UUT s but without Dyno s and Emulators No load for the E-Motor Components are installed

18 TYPES OF E-INTEGRATION TEST SYSTEMS TYPE 1 - PRE INTEGRATION Puma controls all UUT s but without Dyno s and Emulators No load for the E-Motor Components are installed on an UUT table TYPE 2 - E-DRIVE All UUT s with Dyno and Emulators OBC, DC/DC could be in a climatic chamber Battery usually in battery chamber Mario Propst 16 Mai

climatic chamber Battery usually in battery chamber TYPE 4

19 TYPES OF E-INTEGRATION TEST SYSTEMS TYPE 3 2WD/4WD POWERTRAIN OR FULL VEHICLE X-Dynos and Emulators OBC, DC/DC could be in a climatic chamber Battery usually in battery chamber TYPE 4 CHASSIS DYNO Full vehicle with Emulators Mario Propst 16 Mai

20 CONTENT o Applications o System solutions o Product solutions o Use cases o Customer References Mario Propst 16 Mai

In Out USECASE: FUNCTIONAL TESTING Sensors Failure

System Testbed Automation and Test Management Limit

Robustness analysis for SW, HW and their integration o

21 In Out USECASE: FUNCTIONAL TESTING Sensors Failure Insertion Unit FIU CAN Actuators xcu CAN + - Diagnostic System Testbed Automation and Test Management Limit Observation CAN Battery Emulator o Stress & failures o Robustness analysis for SW, HW and their integration o Implementation corporate Maneuver catalogue (e.g. NCAP) Mario Propst 16 Mai

22 USECASE: FUNCTIONAL SAFETY VALIDATION According to ISO to define the ASIL ratings. Mario Propst 16 Mai

23 USECASE: VEHICLE SIMULATION Vehicle : Running a NEDC at low/high battery SOC states Concept testing with non existing battery Mario Propst 16 Mai

24 USECASE: DC CHARGING TEST Trial 1: Communication failed Trial 2: Isolation check failed Trial 3: Charging successful DC Charging Test: Validation of different DC charger suppliers - ISO test - PLC communication - Lock/unlock test Mario Propst 16 Mai

25 USECASE: DC CONTACTOR EMERGENCY TEST DC Bus Voltage Failure BMS: Open DC contactor High Frequency Measurement from voltage and currents HV System Test: Analysis on system level using high frequency measurement equipment Use Case: Switching off the HV Battery during real driving situation. 22ms Check if the currents and voltages are within valid limits. Mario Propst 16 Mai

USECASE: DERATING TEST OF A CHARGING UNIT Max charging current will be reduced due to rise of temperature Temperataure rise De-rating Test: Test of de-rating function for DC charging on different

26 USECASE: DERATING TEST OF A CHARGING UNIT Max charging current will be reduced due to rise of temperature Temperataure rise De-rating Test: Test of de-rating function for DC charging on different component temperature level. The battery should adapt the allowed charging current according the temperature. Derating function will be tested multiple times by deactivating and activating charging. Deactivate/Activate charging Mario Propst 16 Mai

Battery Performance Test: PUMA Open automated battery

27 USECASE: BATTERY PERFORMANCE TEST Control Unit recognize temperature rise of 1 deg Cel. Battery Performance Test: PUMA Open automated battery stress-tests at different SOC states and/or temperature conditions Mario Propst 16 Mai

28 CONTENT o Applications o System solutions o Product solutions o Use cases o Customer References Mario Propst 16 Mai

29 AVL E-INTEGRATION TEST SYSTEM GRAZ Mario Propst 16 Mai

30 AVL E-INTEGRATION TEST SYSTEM GRAZ HV-Battery Climatic Chamber: Temperature range: -30 C up to +70 C AVL estorage Emulator/Tester Systems: 400kW, 1000V, 800A 250kW, 1000V, 800A 20kW, 60V, 350A AVL Mains Emulation: Freely Programmable AC Supply: eg. For US, JP etc 50kVA, 80A Single phase-shutdown HV Measurement System: SAM - Measurement frequency up to 50kHz X-ion E-Power analysis with 2 MHz Fully synchronized with PUMA Open automation system Application/RBS System: VECTOR VN89xx, CANape/CANoe ETAS ESxx, INCA Mario Propst 16 Mai

31 EXAMPLE: BMW E-BIKE TEST CENTER Testing laboratory for validation at component and system levels The user can rapidly test the combination of real components, like battery and e-motor, or partially emulate them Mario Propst 16 Mai

EXAMPLE PORSCHE HV INTEGRATION LABORATORY Testing laboratory for validation of single component and of their combinations Integration of all test equipment by use of the flexible AVL

rapid switching during the test procedure (5-6 times / day) Typical execution of more than 350 tests in two weeks time, with parallel testing of components to save 2-3 days on each

32 EXAMPLE PORSCHE HV INTEGRATION LABORATORY Testing laboratory for validation of single component and of their combinations Integration of all test equipment by use of the flexible AVL Puma automation Tests executed with real or simulated components Components protection by use of highly dynamic DC sources 14 different configurations possible, with automatic and rapid switching during the test procedure (5-6 times / day) Typical execution of more than 350 tests in two weeks time, with parallel testing of components to save 2-3 days on each session Time synchronised measurement and acquisition of all data sources, output in open file format Fast data analysis due to the highly automatized postprocessing Mario Propst 16 Mai

33 EXAMPLE PORSCHE-BERTRANDT HV INTEGRATION TESTBED Mario Propst 16 Mai

rapid switching during the test procedure HV battery can be tested as integrated in the vehicle or in a separate climatic

34 EXAMPLE: HV INTEGRATION TESTBED FOR COMPLETE VEHICLE Testing laboratory for validation of the electrified powertrain, the xev vehicle and its HV battery Usage of real or simulated components Multiple configurations possible, with automatic and rapid switching during the test procedure HV battery can be tested as integrated in the vehicle or in a separate climatic environment of driving manoeuvres Time synchronised measurement and acquisition of all data sources Mario Propst 16 Mai

aentron Energy System 1 to 900 Vdc

aentron Energy System 1 to 900 Vdc The aentron lithium-ion energy system enables the realisation of a modular and scalable lithium-ion battery solution. The management of large lithium-ion batteries systems