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Making the difference in component testing

AVL Inverter TS™

Full test coverage for drive inverters

All high-voltage components in your electrified powertrain require dedicated testing methods and tools. As the inverter controls all driving conditions and is part of the vehicle’s safety-critical functionalities, it is a central component in electric propulsion systems. The demands on the inverter are versatile: It has to be functional, safe, robust, compact and efficient regarding performance and cost. Power electronics, in combination with a high level of signal complexity, require an appropriate test methodology and the use of adequate testing equipment.

Testing with AVL’s Inverter Test System

The AVL Inverter TS provides a test environment in which all inverter functionalities and failure modes can be optimized. This allows easy design and validation of the inverter in the early stage of development as well as optimization of its integration with all other components in the electric powertrain, giving you the most efficient process possible. Moreover, compared to validating the Unit-Under-Test (UUT) in a real-world prototype vehicle, it significantly shortens the time needed.

Using the AVL Inverter Test System

The Inverter Test System includes a digital copy of the e-motor, in this case the AVL E-Motor Emulator (EME), as well as a virtual battery, such as the AVL E-STORAGE. Together, they offer more functionalities and accurate reproducibility than an active load emulator (ALE). There are 3 different ways to transfer the characteristics of your e-motor into the virtual world.

First, in a best-case scenario, the linear parameters – motor type, number of pole pairs, ohmic resistance and inductance – of the e-motor are sufficient to describe it. These specifications are available at an early development stage. Second, at a later development stage, you can use calculation results from a finite element analysis to generate a precise model. Finally, as soon as the real e-motor is available as a prototype, you measure it on an e-motor testbed. In this case, an exact digital copy of the e-motor is generated and you can use it for inverter tests with an AVL E-Motor Emulator.

We offer the complete toolchain for all three of these options. For e-motor measurement AVL delivers e-motor testbeds that already have automated test runs, which let you identify the flux linkage under current variation and generate maps. Efficient and flexible test equipment for the testing of inverters is available, which – in contrast to an ALE – emulates the real physics of an e-motor at the terminals.

Our efficient and flexible Test System

We offer a wide range of tests, including basic functionality tests (development and functional testing of single functionalities and optimization of control algorithms), qualification tests (thermal tests, level of efficiency, overload, active short circuit, control quality under different premises, evaluation of the inverter in a virtual vehicle) and failure insertion tests (failure in rotor sensor, phase short circuits and disruption in the power unit, motor parameter deviations, mechanical failure).

To execute complex and standardized test runs in a reproducible and efficient way, the use of an automation system can help. Our AVL PUMA 2 Inverter™ software is a platform that is specified for the use on the inverter test system. With our tool – unlike an ALE – you can execute your test scenarios consistently, ensuring that the same test runs multiple times. You can be sure your results are based on the correct e-motor behavior, and you can reuse these results from the e-motor testbed on an inverter testbed.

Key Benefits

  • Expand test coverage, while reducing costs and testing time
  • Profit from a wide test range (more than with common testing solutions for inverters)
  • Receive accurate and quick test results
  • Secure reproducibility of tests and test results without any influencing mechanical tolerances