ELECTRIFICATION TESTING SOLUTIONS
IC Engine
HV-Battery
Transmission
Electric Motor
Power Electronics

AVL ELECTRIFICATION TESTING | 2012 | A. Hemery
AVL Testing Solution for Hybrid & Electrical Vehicles
Overview of Products and Solutions

Virtual Vehicle + Environment Platform
AVL InMotionTM (optional)

Battery Test Bed
E-Motor Test Bed
Power Electronics Test Bed
Engine Test Bed
Transmission Test Bed
Powertrain Test Bed
Vehicle Test Bed

AVL e-Storage (DC Power Unit / Emulator / Tester)
Common AVL Automation Platform & Host


E-Motor/Inverter
Battery

ONE TESTING TOOL FOR DIFFERENT APPLICATIONS
AVL E-STORAGE SYSTEM
AVL BATTERY TEST SYSTEMS – Typical Test Bed Setup
Safety systems (optional):
- Safety PLC
- Gas and fire - detection
- water mist fire supression
- Over-pressure flap
e-Storage-System
- Inertisation
Mains Supply
UUT-Battery
Automation
Climatic Chamber
Simulation
(optional)
BCU (BMS)
T / P / U
Thermal camera
Power supply 12V
Measurement
(optional)
LYNX
Coolant
Concerto
Conditioning
(optional)
optional
AVL
InMotion™

AVL BATTERY TEST SYSTEMS – Full vehicle simulation
under Real UUT testing conditions
Climatic Chamber
AVL InMotion
Driving Maneuvers
Environmental
Conditions
Driver Model
Powertrain Model
Virtual Electric
Conditions
Battery
Battery Tester
Hardware
Multi-axis shaker table

AVL BATTERY TEST SYSTEMS – Test Bed Example
3D LAYOUT OF BATTERY LABORATORY &
AVL GRAZ E-MOBILITY CENTER
3D LAYOUT OF BATTERY LABORATORY &
AVL GRAZ E-MOBILITY CENTER

AVL E-STORAGE SYSTEM
AVL E-MOTOR TEST SYSTEMS – Typical Test Bed Setup
e-Storage-System
HCU
Mains Supply
Automation / Simulation
T / P / U
Measurement
UUT-Inverter
or Universal
Inverter
Coolant
Dyno Inverter
Mains Supply
Conditioning
PUMA Open
EMCON
E-Motor
Load Unit
Test System
Mechanics
AVL
InMotion™
Drive Shaft
Options:
- Stall Brake
Options:
Power Measurement
- Angle Measurement
- Climatic Chamber
- HV Battery Enclosure
Speed, Torque
U, I

AVL E-MOTOR TEST SYSTEMS – Standard Mechanical
Layout

20,000 rpm AVL Dynamometer at 2 rpm operation
DynoSpirit 250/4.8-20 Tx
PMM
250 kW
500 Nm
20,000 rpm
0.12 kgm2
25% overload
Water cooled

AVL E-MOTOR TEST SYSTEMS – Test Bed Example
Example:
BSG-Motor

AVL E-MOTOR TEST SYSTEMS – Test Bed Example
Example:
ISG-Motor

AVL E-MOTOR TEST SYSTEMS – Test Bed Example
Example:
Axle-Motor

POWER ELECTRONICS COMPONENTS
Mains supply
Quick
charging unit
Inverter
DC/DC
converter
On Board
Charger
Battery
12V accessories
E-Motor
Mains supply

POWER ELECTRONICS: INVERTER TESTING
e-Storage-System
Mains Supply
T / P / U
Automation / Simulation
Measurement
Coolant
Conditioning
UUT-Inverter
E-Motor
Emulator (e-ME)
PUMA Open
Test System
InMotion
Cabinet
Mains Supply
Power Measurement
Options:
- Climatic Chamber
U, I
- Switch Rack

AVL INVERTER & POWER ELECTRONICS TESTBED
E-Storage
Emulator
EME
E-Motor
Emulator
120 kHz
EME
E-Storage
E-Motor
Emulator
Emulator
e-Motor Model
Operating Conditions:
Design, Temperature, Age,
Failures (shorts, isolation, etc.),

POWER ELECTRONICS: OBC TESTING
e-Storage-System
Automation / Simulation
T / P / U
Measurement
UUT-OBC
Mains Supply
Coolant
Conditioning
PUMA Open
EMCON
Mains
Emulator
AVL
Test System
InMotion™
Cabinet
Mains Supply
Power Measurement
Options:
- Climatic Chamber
- Switch Rack

POWER ELECTRONICS: DC/DC CONVERTER TESTING
e-Storage-System
Automation / Simulation
T / P / U
Measurement
UUT-DC/DC converter
Mains Supply
Test System
Cabinet
PUMA Open
EMCON
Load Bank
AVL
InMotion™
Power Measurement


E-STORAGE EMULATOR FOR POWERTRAIN AND
CHASSIS DYNO TESTBEDS
Battery
Emulator
added to a
Powertrain
Testbed
Test complete electrified powertrains or vehicles with repeatability
Advantages include:
Test run verification
Additional safety
Various operating conditions
Emulate fault conditions
Test different batteries (chemistry, size, etc.)

AVL e-Storage SYSTEM
• High performance (low ripple, rise time)
• Very good EMC (galvanic separation)
<2ms@100kW, <3ms@320kW)
• Parallel operation of up to 4-systems
• Accuracy <0,5%FS(std.)
Master<>Slave
• No switch time between charge (source) <>
• Earth Fault Detection
discharge (sink)
• Main grid voltages (380-480V, 50/60Hz)
e-Storage
Battery Tester
OPTIONS
DC-Power Unit • CAN interface to AVL • Safety Concept ISO13948-1*
• 8 - 800VDC, 600A
Lynx™ Battery Test
• Mech. Main Switch
(2.400A)
• 10-1.000VDCout
Automation
• 0-Volt(0-800/0-1000)customer specific X
• 75 - 320kW
• I/O [V, I, t, p, f, …]
• Interface to
• Accuracy 0,1% FS*
(1.280kW)
conditioning system
• Profibus DP*, EtherCAT*
• Manual
and climatic chamber
• Fast RT Battery Models*
operation/Setpoint
• dyn.AVL Bat. Models (R/C/L)*
Battery Emulator
(V/A/P) from panel
• Matlab/Simulink Interface*
• Interface to ext. Bat. Models*
• Charge
(source)/disch
• Internal electrical
• BMS Restbus Simulation*
arge(sink)
Battery Model "Ri“
• Multi Current Range
• CAN
(std.)
• Water Cooling
(100Hz),Ethernet
• PDU (Remote control in Test
cell with UUT connection) *
U P G R A D E ( at any time *)
• Discharge Unit

Reference List
ITS
≥ 180pc AVL e-Storage and
automation Systems in 18
countries since 2009
THANK YOU FOR YOU ATTENTION !
AVL ELECTRIFICATION TESTING | 2012 | A. Hemery