NVH Testbed for High-speed E-motors
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NVH Testbed for High-speed E-motors
Together with Flanders Make, Tectos has developed a testbed for NVH tests on e-motors which safely covers measurements up to speeds of 20,000 rpm in transient operation. It is built as a real-time capable hardware-in-the-loop platform and allows for comfort optimizations, as well as tests on the inverter in conjunction with the e-motor.
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© Tectos
AUTHORS
Dr. Dieter Höfler is General Manager and Head of Research & Development at Tectos GmbH in Graz (Austria).
Electromobility is becoming in creasingly important with more and more new vehicles being equipped with electric drives. When it comes to the development of purely battery-powered electrical vehicles, one of the biggest challenges that developers are faced with is increasing the efficiency of the drive and also the battery range of the vehicles [1, 2]. For reasons of efficiency, when it comes to e-motors and inverters for automotive applications, the trend is going toward higher speeds and switching frequencies which can help to reduce mass while achieving a high performance. In turn, the increased per formance helps the drive reach the high g
Dipl.-Ing. Stefan Maxl is Scientific Assistant to the Research & Development Department of Tectos GmbH in Graz (Austria).
driving dynamics desired by the driver. However, these measures also increase the risk of NVH phenomena occurring which are perceived by the driver and passengers in the vehicle as disturbing noises or vibrations. The high speeds and dynamics of electric drives also present new chal lenges when it comes to testbed technol ogy. Tectos has developed an e-testbed for NVH tests which safely covers mea surements up to speeds of 20,000 rpm in transient operation. The testbed has been constructed as a real-time capable Hardware-in-the-Loop (HiL) platform. This means that the NVH behavior of e-drive components can be tuned and www.springerprofessional.com/automotive
Specifications
Unit
Value
Rotor inertia (dynamometer)
kgm²
0.075
Number of pole pairs
-
3
Maximum speed
rpm
20,000
Minimum switching frequency
kHz
12
Maximum power
kW
320
Maximum torque
Nm
550 (for 60 s, nominal 500)
Maximum weight of the UuT
kg
100 (with reduced speed)
TABLE 1 Testbed technical specifications (© Tectos)
validated before being integrated into the vehicle. In comparison to a series of tests on the road, the frontloading process reduces costs and increases the reproducibility of the measurement results. DESIGN OF THE TESTBED
TABLE 1 contains the general specifica tions of the testbed. It is built so that the drive unit that is to be tested (Unit under Test, UuT) can be connected via a shaft to a torque sensor that is coupled with a dynamometer, FIGURE 1. This design guar antees precise test cycles and provides precise torque and speed measurements. The main components of the testbed are the dynamometer, a connecting
CV shaft, which rotates with the UuT or dynamometer speed, an interchange able intermediate bearing unit, the torque sensor and a spline
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