High Speed Dynamometer System Solution for
E-Drive System of EV & HEV

1. Model Selection of High Speed Dynamometer

1. High-speed Dynamometer Selection

1. Power and torque characteristic test of the motor with controller
2. Temperature rise test of the motor with controller
3. Stall test of the Motor with controller
4. Design and verification test of the control strategy for the controller
5. Maximum speed test of the motor with controller
6. Feedback test of regenerative braking energy for the motor with controller
7. Motor external characteristic test
8. Development and matching optimization test of the powertrain for the motor and controller
9. Performance and calibration test of the powertrain for the motor and controller
10. Efficiency map test
11. Accelerated response test
12. Torque response test
13. Durability test under steady-state cyclic loading

3. System Framework

4.1 High Performance Electric Dynamometer 

4.2 High Dynamic Control System 

4.3 Convenient electric parameter measurement system

4.4 Measurement control accuracy

1. Torque measurement control accuracy:±0.05%FS
2. Speed sensor pulse resolution:1024/600pprppr
3. Torque control accuracy:±(0.5~1)%FS
4. Speed control accuracy:±(0.01~0.05)%FS
5. The max vibration value of dynamometer(RSM):≤2mm/s(no load),≤3.5mm/s(load)
6. The bearing support temperature rise:≤35ºC
7. The max vibration value of the bearing support(RSM):≤2mm/s(no load),≤3.5mm/s(load)
8. DAQ sampling rate:1kHz
9. Current measurement channel:4/6
10. Voltage measurement channel:4/6
11. Measurement accuracy of power analyzer: ±0.05%
12. Temperature sensor measuring range: -50ºC~200ºC
13. Measurement accuracy of temperature sensor: A class
14. Vibration sensor measuring range: 0~20mm/s

4.5 High Precision Mechanical Structure 

4.6 High Precision And High Speed Bearing Support 

1. Four high-speed angular contact ball bearing
2. Spring preloading for bearing
3. The temperature rise is less than 35ºC
4. vibration on the maximum speed is less than 2 mm/s
5. Grease lubrication, maintenance-free 
6. continuous operation for 20000 hours

4.7 Perfect Fault Monitoring Function

1. Real-time monitoring of the dynamometer including: the front and rear bearing temperature, current, voltage, speed and the torque.
2. Real-time monitoring of the temperature and vibration of the high speed bearing support in the middle.
3. Real-time monitoring on the vibration of the tested motor..
4. Safety guard closure detection, to get the Interlock protection with dynamometer.
5. Safety protection measures of the controlling system including: short circuit, leakage, power failure, overcurrent, overvoltage.
6. The system software has the function of safety detection. When the monitoring values exceed the threshold, it will alarm immediately. Generally, the system has three-level protection function.

4.8 Perfect measurement control software

1. Speed control
2. Torque Control
3. Temperature monitoring
4. Speed monitoring
5. Safety function
6. dynamometers
7. Suitable for vehicle test bench
8. Suitable for passenger car and truck test bench
9. Standard interface for communication with software on the host computer
10. Limit monitoring from the tested samples to the test bench, ensure that when the speed
11. abnormality occurs ,the tested samples can switch to the safe state in a very short time.
12. Restore to safe condition.
13. System Interface:

1. Communication interface with the environment chamber;
2. Communication interface with the cooling system;
3. Communication interface with the battery simulator;
4. Communication interface with the inverter;
5. Four-way CAN bus which can communicate with the test piece.
6. One-way Ethernet communication interface;
7. Provide appropriate cables.

4.9 Easy installation

4.10 Shafting alignment measures

1. Laser alignment
2. Have fine-tuning mechanical structure

4.11 Shaft Dynamic Balance Measures

1. 1. Flange designed on shaft system with uniform distributed threaded holes for counterweight
   2. The on-site dynamic balancing instrument used to gain the dynamic balancing

4.12 DC Bidirectional Power

4.13. Cooling system of tested motor

1. Temperature regulation range: 5 ºC~100ºC.
2. Temperature control accuracy:≤± 2ºC.
3. Flow regulation range: 5 ~ 40L / min (can be adjusted manually).
4. Pressure range: 250kPa.
5. RS485 supports local + remote control mode.
6. Complete machine structure: water-cooled integrated structure design, equipped with casters, easy to move.
7. Compressor brand: France Taikang, Germany bizel or Germany blog.
8. Material of refrigeration box: sus#304.
9. Temperature and pressure detection position: liquid inlet / outlet;
10. Flow monitoring position: liquid outlet.
11. Target temperature acquisition: liquid outlet temperature.
12. Safety protection: high and low temperature alarm; Alarm for insufficient liquid level of refrigeration tank; Alarm for too high and too low outlet flow;
13. Alarm for too high and too low outlet pressure; High and low pressure monitoring and alarm of refrigeration system.