At the electric power level, the real power stages are included in the test and only the motor is emulated by an electronic load. For this reason, the device under test does not need to be modified and only minor safety restrictions apply compared to a mechanical test bench.
The DS5380 Low-Voltage Electronic Load Module is optimized for high-speed operation as required for emulating electric motors, such as those in electric steering systems. It can work as both a current sink and a current source to provide bidirectional current flow, i.e., it consumes or generates real currents of or for the motor ECU outputs. The DS5380 Low-Voltage Electronic Load Module can be combined with a dSPACE FPGA base board. In combination with the XSG Electric Components Library, these boards provide the fast reaction times required for controlling electric machines. On the FPGA base board, the FPGA computes parts of the simulation model for the electric machine, e.g., from the XSG Electric Components Library, and operates the electronic load module.
The DS5381 Low-Voltage Electronic Load Unit emulates motor and generator currents at voltages of up to 60 V. Highly dynamic switching between the current and voltage control modes makes it possible to emulate floating brushless DC (BLDC) motor phases without additional booster components. With a voltage range of up to 60 V, the unit is also ideal for use with higher onboard vehicle voltages of 48 V.
The unit is perfect for emulating three-phase electric motor units. Energy recuperation is also included to boost the energy efficiency of the overall system. Typical test application areas are electrically supported steering, starter and generator systems, and mild hybrid drives. Multiple loads can be operated in parallel to achieve higher electric currents in the electronic load.
To make the automated tests more perceptible for the developers, the simulation systems can be extended with 3-D visualization software, a steering wheel, or a complete cockpit for the developers to sit in and “drive” the system.
Simulation models such as ASM Vehicle Dynamics make the system behave realistically.
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