Inverter Test System

Development is just one aspect. Just as crucial: The test strategy. In a suitable test environment. And in detail.

“The e-motor emulator forms the core of the system.”

Short set-ups. Fast results. Change the virtual motor with a mouse-click. All scenarios can be represented in detail. And successfully tested. So that insights for development are directly tangible – fast, precise, reproducible. This is what the SPS Inverter Test System stands for. It supports a parallel development process for drive inverter and e-motor.

Exhaust all possibilities. Bundle results. That is revolutionary.

While the e-motor is still under development, the inverter can already be tested in parallel. Connected to the virtual motor. With a load as if on a machine test stand. But better. Characteristics values can be derived from the e-motor’s construction data and fed into the emulator; a digital copy of the e-motor. Work can begin immediately: Inverter tests, power tests, fault scenarios. Without restrictions. Without compromise. Although the e-motor does not exist in a physical form. Crucial advantage: Early results save enormous amounts of time and costs. Test results from this early phase can be used to optimise the e-motor design. And automated tests can run day and night, based on real driving profiles of test vehicles.

Realistic emulation – this attribute is ingenious.

Since it is model-based, the emulator can emulate different e-motor types using software-based mathematical models. The specific character is obtained through configuration of the parameters. Particularly important: the correct emulation of the e-motor’s dynamic behaviour. In real-time. Extremely important for control tests or special tests: active short-circuit and cable short- circuits. And all this in the laboratory. Without mechanics. Without a dynamometer. But better. The test systems have been designed for a wide range of tests and a wide range of inverters and converters. They are hence extremely flexible. A power range from approximately 10 to more than 400 kW and voltages of more than 900 V and currents of 1,200 Arms or more can be reliably covered.

A “virtual e-motor on a virtual load system” – unbeatable for inverter tests.

As astounding as it may seem: The e-motor emulator emulates many inverter test cases more precisely than a real motor on a dynamometer could. How? All dynamometers have their own peculiarities. Limited by mechanics. Limited by control algorithms. That makes the e-motor emulator better. Extreme dynamics enables precise emulation of the original system. The dynamic response of an e-motor emulator is several powers of ten better than a mechanical load system. Since the test system does not need any rotating parts, it is ideal for system tests or end-of-line tests.

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