Low-Voltage Testing

Low-voltage emulation of e-mobility components

Using multiple low-voltage electronic loads in parallel makes it possible to reach up to several kilowatts of power. Typical test application areas include electric power steering (EPS) systems, starter and generator systems, two-wheelers, secondary drives, and mild hybrid drives.

dSPACE has years of experience in power hardware-in-the-loop testing: In addition to our high-voltage approach, we also offer smaller systems based on the DS5380 Low-Voltage Electronic Load Module and the DS5381 Low-Voltage Electronic Load Unit, which are suited for emulating and testing ECUs with low voltages of up to 30 V and up to 60 V, respectively.

The electronic loads can either be completely integrated into a standard HIL cabinet or combined with several external components, such as high-current failure insertion units (FIU) or climate chambers.

Application Areas

Typical applications for our low-voltage systems are dynamic tests at the power level of the following:

  • E-bikes
  • E-scooters
  • Auxiliary drive systems
  • Mild hybrid drives
  • Electric power steering (EPS) systems
  • Brake-by-wire applications
  • Electric pumps
  • Electrically automated manual transmission

Unique Features

  • Outstanding and very realistic current emulation
  • Identical modeling environment for tests on the signal level and the power level
  • Specifically tailored for hardware-in-the-loop (HIL) simulation at the power level
  • Current-based emulation for simulating variable motor inductances without the necessity for switching or exchanging any hardware components
  • Support of discontinuous conduction mode for the emulation of sensorless brushless DC (BLDC) motors
  • Safe test conditions due to safety mechanisms for power electronics

You can choose from a variety of test scenarios for your application:

  • Functional tests
  • Load tests
  • Manipulation of feedback signals, such as the position sensor offset angle, during simulation
  • Tests of controller robustness and control limits by adjusting the relevant motor parameters, such as inductance, resistance, and flux, during simulation
  • Tests of critical operation conditions, e.g., simulation of electrical faults
  • True-to-life simulation without mechanical limitations, e.g., simulation of mechanical blocking
  • Conformance tests

Our Products

DS5381 Low-Voltage Electronic Load Unit

Low-voltage electronic load unit for the power HIL simulation of electric machines (voltage range: up to 60 V)

DS5380 Low-Voltage Electronic Load Module

Low-voltage electronic load module for power HIL testing of low-voltage and low-power auxiliary motors (voltage range: up to 30 V)

Use Case

Mild Hybrid Testing

Model-based approach for low-voltage testing of mild hybrid systems

Support Contact Information

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