Electric Test Bench

High-voltage power hardware-in-the-loop

dSPACE offers ready-to-use solutions for testing controllers and power electronics throughout the complete range of electric vehicle components. These solutions are specifically tailored for hardware-in-the-loop (HIL) simulation at power level. Power HIL systems from dSPACE close the gap between signal HIL testing and testing on dynamometers or in prototype vehicles.

Hardware-in-the-loop (HIL) systems with high-voltage electronic load modules from dSPACE provide highly dynamic emulation of electric motor, battery, and grid components with several hundred kilowatts of power and voltages higher than 1,000 V. All components of hybrid and fully electric drives can be represented with a real energy flow.

These high-voltage power hardware-in-the-loop (PHIL) capabilities make dSPACE a unique provider of single-source, ready-to-use simulation solutions for the complete range of electric vehicle drives. Power hardware-in-the-loop testing is nothing new for dSPACE. The approach is similar to our smaller systems based on the DS5380 and DS5381 modules, which are suited for emulating and testing ECUs with low voltages of up to 30 V and up to 60 V, respectively.

Typical applications for the dSPACE high-voltage systems are dynamic tests at the power level of:

  • Automotive traction motor controllers
  • Charging stations and onboard chargers
  • DC/DC and AC/DC converters
  • Industrial servo controllers

These applications can be used in a variety of test scenarios:

  • Functional tests
  • Load test (burn-in, end-of-line, controlled fault conditions)
  • Test of controller robustness (parameter variation)
  • Test of critical operation conditions

An open (Simulink®/Xilinx®) library from dSPACE provides the required simulation models, from FPGA models for motors and position sensors using the XSG Electric Components Models to the dSPACE Automotive Simulation Models (ASM) for batteries and complete powertrains.

  • Modular approach for highest flexibility at full power
  • Outstanding and very realistic current emulation
  • Identical modeling environment for tests on signal level and power level
  • Specifically tailored for HIL simulation at power level
  • Current-based emulation for simulating variable motor inductances without the requirement for switching or exchanging any hardware components
  • Efficient operation thanks to a circular energy flow without energy recovery to the mains: power supply requires less than 20% of emulation power
  • High power density per emulation rack, leading to a small overall system footprint
  • Safe test conditions due to safety mechanisms for power electronics
  • In-house development of hardware and software by dSPACE, resulting in a turn-key system from one provider.

Key Benefits

The high-voltage load setup based on the DS5385 and DS5386 High-Voltage Electronic Load Modules features a compact and modular design. The compact units can be used flexibly with regard to currents per phase and number of phases as well as the type of source to be emulated. The system’s scalability allows for a combination of multiple high voltage cabinets to further increase the test system’s power. Using the same hardware for the emulation of loads, such as electric motors, and sources, such as batteries, makes the systems cost-effective and easy to maintain. The energy flow in the system circulates without complex grid feedback, leading to high efficiency and minimum load on the mains supply. All these features result in an improved test coverage at reduced costs (compared to a dynamometer), reduced development times, and improved safety (LV123 and ISO/DIS 21498).

DS5385 and DS5386 High-Voltage Electronic Load Modules

High-voltage electronic load modules for power HIL simulation – ideally suited for testing electric motor controllers, including power electronics (voltage range: up to 800 V for DS5385 and up to 1,000 V for DS5386)

DS5381 Electronic Load Module

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

DS5380 Electronic Load Module

Low-voltage electronic load module for the HIL simulation of electric machines (voltage range: up to 30 V)

  • Electric Test Bench Product Information, PDF, English, 1667 KB
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