Electric Motor HIL Solution

Processor-based electric motor simulation

The EMH (electric motor HIL) solution is based on the DS5202 FPGA Base Board. It gives you all the I/O channels that are needed for HIL simulation of electric motors, such as high-precision digital capturing of 3-phase PWM signals and position sensor simulation, plus several digital and analog I/O channels.

High-precision and fast digital capturing of 3-phase PWM signals
Simulation of various position sensors
High timing resolution

Overview

The EMH (electric motor HIL) solution is based on the DS5202 FPGA Base Board. It gives you all the I/O channels that are needed for HIL simulation of electric drives, such as high-precision digital capturing of 3-phase PWM signals and position sensor simulation, plus several digital and analog I/O channels. It combines the features of the DS5202 PWM and PSS solutions with many additional multipurpose channels, and enables efficient testing of electronic control units (ECUs) for electric drives on a single I/O board.

Key Benefits

The DS5202 EMH solution combined with a simulation model allows you to measure the signals of up to 2 electric machines with up to 8 power switch control signals each, for example, IGBTs (insulated-gate bipolar transistors). There is a choice of three operating modes: software polling, external interrupt source, and internal pulse center interrupt source, meaning clock generation based on the measured PWM signals, which is the most suitable way of avoiding beat effects.

The current feedback signals for the ECU can be simulated by using the board’s fast analog output channels. For position sensor simulation, the board is equipped with four independent angular processing units (APUs) that receive the angular velocity from the model and calculate the position signal. Since each APU’s sample time is 25 ns, it provides a position signal with a high timing and angular resolution.

Technical Details – PWM Measurement

Parameter	Specification
Number of channels	16
Resolution	Max. 12.5 ns (80 Mhz) - 400 ns (adjustable)
Center-aligned capture groups	2 (each group has 8 channels)
Input voltage range	0 ... +30 V
Adjustable thresholds	+1 ... +8.5 V
Input resistance	24 kΩ
Protection	±50 V

Technical Details – Position Sensor Simulation
APU (Angular Processing Unit)

Parameter	Specification
Number of independent APU units	4
APU angle precision	32 bit
APU update rate	25 ns / 40 MHz
APU speed range	Up to ±292,969 rpm

Analog Sensor Simulation

Parameter	Specification
Number of Analog Sensors	1
Sensor types	Resolver, sine encoder, user defined waveform
Number of pole pairs	1 ... 16,383
Adjustable angle offset	-360 ... +360°
Resolver accuracy	0.1° (depending on the settings)
Resolver transformation ratio	0 ... 16 (typ. 0.5)
Resolver Failure Simulation
Additional delay for resolver feedback signals:	Up to 409.6 µs
Amplitude error (dos - degradation of signal):	-100 ... +100%
Phase error (lot - loss of position tracking):	-90 ... +90°
User defined waveform resolution (16,384 values)	0.02197°
Analog Input (Resolver Excitation Input)
Channels:	1 channel
Input range:	±30 V (differential)
Resolution:	14 bit pipelined
Sampling rate:	10 MSPS
Protection:	±50 V
Resolver excitation-coil simulation:	220 Ω / 2 W
Analog Output (Cosine / Sine)
Channels:	2 channels
Output range:	±10 V single ended (±20 V differential / transformer mode)
Resolution:	12 bit (of user specified output range)
Sampling rate:	10 MSPS
Output mode:	Transformer or direct output
Protection:	±50 V
Analog Output (Index)
Channels:	1 channel
Output range:	±10 V single ended (±20 V differential)
Resolution:	12 bit
Sampling rate:	10 MSPS
Output mode:	Direct output (with inverted output stage)
Protection:	±50 V

Digital Sensor Simulation

Parameter	Specification
Number of digital sensors	1 (+3 independent angle based outputs)
Sensor types	TTL encoder, hall encoder, user defined waveform; (+3 independent angle-based outputs)
Number of pole pairs	1 ... 16,383
User defined waveform resolution (8,192 values)	0.0439°
Digital Output
Channels:	6 channels (3 channels with inverted output stage)
Output range:	0 ... +5V
Sample rate:	25 ns / 40 MHz
Output current:	20 mA
Protection:	±50 V

Serial Sensor Simulation

Parameter	Specification
Number of serial sensors	1
Sensor types	SSI-Encoder, Hiperface Encoder, EnDAT Encoder
Number of multi turn bits	0 to 14
Number of single turn bits	1 to 18
RS485
Channels:	2 full-duplex channels
Maximum data rate:	Up to 10 Mbps
Protection:	±50 V

Technical Details – Multipurpose Channels

Parameter	Specification
Analog outputs	6 channels; ±10 V output voltage range; 12 bit; 10 MSPS; differential; Protection ±50 V 1 channel; ±10 V output voltage range; 14 bit; 1 MSPS; single ended; Protection ±50 V 3 channels; ±10 V output voltage range; 12 bit; 10 MSPS; Protection ±50 V; shared with analog sensor simulation
Analog inputs	4 channels; ±30 V input voltage range; 16 bit; 1 MSPS; differential; Protection ±50 V 2 channels; ±30 V input voltage range; 14 bit; 10 MSPS; differential; Protection ±50 V; shared with resolver simulation
Digital inputs	1 channel; 0 ... +30 V; Protection ±50V 16 channels; 0 ... +30 V; Digital or standard PWM inputs; 12.5 ns (80 MHz) resolution; Protection ±50 V; shared with center aligned PWM measurement units Global adjustable threshold voltage +1 ... +8.5 V
Digital outputs	10 channels; 0 ... +5V output voltage range; Protection ±50 V 6 channels; 0 ... +5 V output voltage range; Protection ±50 V; shared with digital sensor simulation 3 channels; 0 ... +5 V output voltage range; Protection ±50 V; shared with digital sensor simulation; Mode: Digital out or PWM out (25 ns resolution)

A typical use case is a hardware-in-the-loop (HIL) simulation where the electric motor including the electronic power stage is simulated by means of the dSPACE modular real-time hardware. Simulation models like dSPACE Automotive Simulation Models – ASM Electric Components Library are used for simulating the electric components. The gate driver signals (typically PWM signals) coming from a controller are measured by the DS5202 EMH solution, and calculated motor current signals are sent back to the controller by means of analog voltage signals, which can also be provided by the DS5202 EMH solution. In addition, the DS5202 EMH solution provides the necessary position sensor signals for the ECU.