Hybrid Test Bench
ATENA

SILVER ATENA
Sales-Team
+49 89 189600 - 3322
product@silver-atena.de


Solution


The hybrid test system developed by SILVER ATENA emulates the electric properties of an electric motor with a capacity of up to 100 kW.


The main component of the hybrid cabinet (see diagram 1) is the electric motor simulation SimuleD® (simulated electrical drive). SimuleD® emulates the three motor phases U, V and W of the hybrid control unit just like a real engine and simulates the varying load situations with real current flows of up to 400 A. The test system returns the motor temperature (as a simulation of a PT100 or NTC sensor) as well as the rotor condition to the hybrid drive control unit.


In addition to the behaviour of an electric drive, SimuleD® also emulates the 400V board system. By integrating board system with motor in SimuleD®, the electrical energy can recirculate the absorbed energy between control unit and SimuleD®.


Result

Your hybrid drive control unit can be tested dynamically with real loads directly in the lab. There are no restrictions in terms of operating state, functions or safety.
The solution also allows you to test each operating state under real, reproducible conditions. This includes not only the four-quadrant operation but also the simulation of various errors and the coupling of the control unit to an HIL test system with an entire vehicle model.

  • Quick and safe testing of hybrid drive control units during the development
  • Cost-effective alternative to the machine bed with load unit
  • Quick and flexible adaptation to other motor types
  • No security hazards for the operator (electrical or mechanical), no rotating parts
  • No high-voltage training required for operator/developing engineer
  • Secure partitioning of low voltage and high voltage areas
  • Minimum power consumption thanks to current recirculation, no refeeding to the supply system required
  • Can be operated in conventional electronic labs - no special provisions required
  • Eco-friendly development thanks to significantly reduced energy consumption

Attributes

    • Emulates the electric properties of an electric motor with a capacity of up to 100 kW (SimuleD®) and real current flows up to 400 A.
    • Simulates the motor temperature and the rotor condition (resolver sensors)
    • Bord system simulation (400 V)
    • Minimum power consumption thanks to current recirculation, no refeeding to the supply system required (the electrical energy can recirculate the absorbed energy between control unit and SimuleD®)
    • Hardware - Software integration tests

    Hybrid Test Bench

    Conclusion

    The hybrid test bench offers the possibility of testing hybrid drive control units under real loads. This does not require the construction of a vehicle/prototype or a test bench with machine bed and load unit. 

    Operating without rotating parts, the hybrid drive control unit is tested with real loads and current flows. The hybrid system acts like a real motor to the control unit.


    Scope

    • Application software function tests for the hybrid control unit
      - The developing engineer can test functions directly at the workplace without requiring the resources labcar/vehicle
    • Hardware prototype test for the hybrid control unit (commissioning of hardware prototypes)
      - New hybrid control units can be commissioned with real loads (400 V up to 400A) without having to be fitted into the vehicle (alternative to the machine bed with load unit)
    • Hardware - Software integration tests
      - First system integration tests of new versions directly at the workplace
    • Vehicle development: function-oriented testing
      - Safety-relevant driving dynamics tests can be tested in advance using the labcar
      - Electrical integration into the vehicle complex (labcar)


    SILVER ATENA