Powertrain Electric Vehicle (EV)
The Powertrain Electric Vehicle (EV) segment includes all the components required to move the electric vehicle.
Test systems for the electrical components in the powertrain are indispensable in development and production. They are an important element in ensuring quality and safety of electric vehicles.
Electric Motor / Generator
The engine is the electric drive in the electric vehicle.
Modern electric vehicles use brushless AC motors, which means that, unlike brush motors, there is no direct electrical contact between the moving rotor and the fixed stator. As a result, it has less friction and a longer endurance.
The electric motor can also act as a generator and be used to charge the accumulator (recuperation): during braking, the kinetic energy is recovered and fed into the battery.
The heart of the electric car
The battery (or storage) is the heart of the electric car and provides the energy for its movement.
These high-voltage batteries have output voltages between 400 V DC and 800 V DC. They consist of numerous battery cells connected in parallel and in series. Lithium-ion batteries currently dominate electric vehicles. Research is being conducted worldwide to improve the performance of these batteries. However, alternatives based on other raw materials are conceivable.
The AC/DC converter enables / supports the charging process of the energy storage.
As the name suggests, it converts alternating current into direct current for the battery. AC charging stations can be found especially in cities or in semi-public places such as company premises or car parks. The AC/DC converter enables safe and convenient charging of electric cars.
It is installed as an individual electrical component or integrated in other components in the electric vehicle.
Do you have concrete test requirements in the field of electromobility?
Do not hesitate to contact me. I am looking forward for your interesting requests.
The converter is a component for transforming the high-voltage intermediate circuit voltage into the classic 12 V voltage range of conventional vehicles.
The 12 V voltage is also required in electric vehicles, since most electrical components in the electric vehicle are still operated at this voltage (e.g. fans or infotainment systems). This converter can also be part of another component in the powertrain range.
Electric drive motors are controlled by inverters, which are designed as power electronics including control logic for electric motors.
Inverters convert the 3-phase alternating voltage of the generator (i.e. the electric motor during braking) into a DC voltage for charging the battery. Similarly, when the electric motor is driven, the DC voltage of the battery is converted into a 3-phase AC voltage.
Test benches for inverters are an elementary component of electromobility. Function tests, quality and endurance tests with or without environmental simulation (e.g. climate) as well as end-of-line test systems for different performance classes of inverters belong to the task spectrum.
Expertise for inverters from GÖPEL electronic
The core task in the functional test of the inverter is to simulate the system components such as the energy source (battery) and the load (electric motor) and make them available for the functional test of the component.
The simulation is carried out with original loads (stators) or with passive or electronic equivalent loads, which in turn are defined by the phase outputs of the DUT (3/6-phase).
By replacing the original loads with an electric machine emulator and the energy source with a battery emulator, real load scenarios can be simulated. An additional special feature when handling inverters is the provision of a coolant supply on the test specimen, as this must be actively tempered.
In combination with wear-free contacting, suitable for production, and coupled environmental simulation, this results in highly complex overall test systems.
In its test environment, the end-of-line test realizes all necessary simulations, for example the energy source (battery) or the consuming electric motor as a load.
The functions are tested automatically. The test object is also automatically delivered and contacted.
Once the function test has been completed, the DUT is transferred back to the transport system for further processing. The necessary communication to the DUT is carried out via interfaces on the function test system.
The residual bus simulations required for the automotive bus systems (e.g. CAN-FD, LIN, FlexRay) are implemented by us as an end-of-line system according to the requirements of the function test system.
Run-in systems perform a reduced function test for inverters. This reduced function test corresponds to the function test, but with the focus on guaranteeing and monitoring general functionality.
The run-in system simulates a battery or electric motor. The simulation of the vehicle environment is also performed using automotive bus systems.
An essential component of the run-in systems is an environmental simulation by a climatic chamber. This makes it possible to include any climate profile in the test. In connection with a production-suited, wear-free contacting with coupled environmental simulation via the climate chamber, we offer you a comprehensive test system.
Battery Junction Box (BJB)
Battery Junction Box (BJB) is a switching unit for the battery in an electric vehicle. It connects or disconnects the components in the vehicle, which need energy from the battery.
With one or more bus interfaces, this component is networked with the entire vehicle. The BJB is usually a switching box that switches the high-voltage connection on or off. It ensures that the high voltage is only applied to the necessary contacts when the ignition is switched on.
In these vehicles the high voltage can be up to 1000 VDC. The BJB has a safety function: in case of danger it disconnects the high-voltage battery from the electrical system including all electrical components of the vehicle.
For example, in the event of an accident it must be ensured that no high voltage is present in the vehicle in an uncontrolled state in order not to expose rescue workers to any danger.
Competences for BJB from GOEPEL electronic
With an End-of-Line test system (EOL test) for Battery Junction Boxes we bring safety into the electric vehicle.
All necessary functions of the BJB component are checked by the EOL tester. For example, the correct on/off switching of the high voltage switching elements is tested.
The safety shutdown of the high voltage is checked with a simulated crash pulse. With the aid of a corresponding load simulation the current capacity of all high voltage paths is tested.
We create the residual bus simulation of the automotive network environment according to the specifications of the project and implement it in the test. This is the only way to ensure correct communication with the DUT during the test. The BJB is contacted by an automated handling system.
Since the energy storage is powered with high voltage, also the BJB is connected to these voltages. An insulation voltage test is therefore absolutely necessary as a safety test with a correspondingly high test voltage.
This high voltage can be up to 4000 V DC.
With our test systems for the high-voltage test of the Battery Junction Box, we prove the insulation voltage resistance and a required insulation resistance.
With a function test for the Battery Junction Box we check all functions of this component. The test system provides voltages up to 1000 V DC and 50 A in the high-voltage range.
These power supplies simulate a battery. With the simulated battery the on/off switching of the high voltage switching elements as well as their current carrying capacity is checked at the BJB.
The crash shutdown function of the Battery Junction Box serves as a safety function and is used to disconnect the battery from the vehicle's high-voltage network in case of danger. The test of this function is performed with a specially generated crash impulse, the parameters of which can be flexibly adjusted.
One component of the Battery Junction Boxes is the so-called insulation monitor, which must also be tested. Up to 1000 A flow through the BJB during normal operation. In order to check these, the current carrying capacity is realized by measuring the contact resistances. The measurement technology is designed in such a way that contact resistances in the µOhm range are monitored with sufficient accuracy. In addition, the test system performs the residual bus simulation.
We realize hard- and software for the adjustment of high current sensors, which measure currents between -800 A DC and +800 A DC.
These are sensors which record the current consumption from the storage and provide it to other components in the vehicle.
This hardware and software can be integrated into function test systems.