Powertrain Testing

End of Line Test Inverter driven by power Hardware in the Loop

Minimize your risk

Our new, cost-efficient and eco-friendly test solution for inverters is the first of its kind on the market: test stands with an electronic load emulator (ELE) that are based on an off-the-shelf industrial inverter. The device that is being tested is maximally loaded and therefor can be tested under real time circumstances.

With the electronic load emulator we are able to replace the functions of an original e-motor in a car with an electronically-controlled load.

Thomas Kruse, Head of Product Engineering Test, thyssenkrupp System Engineering

Testing under real conditions

In the series production process, End of Line Tests for inverters are used to check the functional integrity of inverters. Therefore, they need to simulate all kinds of possible situations under real conditions - a complex system that, up until now was mechanically carried out with an e-motor, coupled under full load to a dynamometer.

PHiL modular and scalable software solution

PHiL modular and scalable software solution

Inverter test in serial production environment

We made it possible to bring the advantages of the PHiL (Power Hardware in the Loop) motor emulator from the lab into the production environment – cutting the costs of a lab PHiL. PHiL is used for testing a hardware power component under real conditions. The method is able to simulate higher power flows than HiL or Closed-Loop-Tests. Thus, the possibilities of power transfer between devices under test and the simulation of the electric circuit in the industrial inverter is much higher.

Benefits of our solution

Cost-efficient
Cost-efficient

Due to our efficient energy re-cycling only 20% of the real testing power will be taken from the grid minimizing your energy cost. The complete elimination of mechanical components and turning parts in the test stand minimizes your maintenance cost.

Space-saving
Space-saving

The complete elimination of mechanical load motors minimizes the footprint of the test station. The electrical power cabinets can be placed independent from the test position minimizing the influence on your line layout.

Energy-efficient
Energy-efficient

Due to our smart energy re-cycling with a common DC-Link, energy gets recovered and feeds the DC-Voltage of the Device-under-Test again – a circular energy flow. Only 20% of the real testing power will be taken from the grid.

Noiseless
Noiseless

Where there are no fast turning parts there are no sources of loud noises.

Spare part highly available
Spare part highly available

Our innovative electronic load system is based on a standard off-the–shelf industrial inverter which guarantees short delivery times. Our special software can be downloaded to the spare part within minutes.

Features

DC-Input
Battery Simulation
AC-Load
Electronic Load Emulator
Test voltage range 30 – 800 VDC200 – 800 VAC
Test current (max. current) ±380 ADC (±450 ADC for 30 seconds)±450 ARMS (±650 ARMS for 30 seconds)

Features

DC-Input
Battery Simulation
AC-Load
Electronic Load Emulator
Test voltage range 30 – 800 VDC200 – 800 VAC
Test current (max. current) ±380 ADC (±450 ADC for 30 seconds)±450 ARMS (±650 ARMS for 30 seconds)