E-Drive Testing Solution Motor & Battery

Built for Excellence

Frankonia’s

E-Drive Testing Solution (Motor and Battery)

Features at a glance: ü Semi-Anechoic Chamber and Test System ü Full compliant with EMC standards ü ü ü

Prepared for tests on motors (fixed or mobile load machine) Prepared for tests on batteries (several test cases) Prepared for any EMI/EMS test procedure

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Requirements for EMC E-Drive Testing Chamber (EDTC)

C: A complex EMC test setup from Frankonia Standards CISPR & ISO • CISPR and ISO conform test setup • Respect of different test scenarios • Interference suppressed instruments • Secure test environment for EUT, chamber and staff • Future-proof functionality

Load Machine (Dynamometer)

CISPR ISO

LM

• fixed version up to 350 kW • mobile version up to 120 kW

EDTC Battery System

AC

BS

Anechoic Chamber • dedicated for component tests acc.to CISPR 25 • or for vehicle tests acc.to CISPR 12 • or both in a single solution

TS

• Battery simulation • Battery test • Charging emulation • for components and vehicle tests Available power range: • 300 A or 600 A • 100 kW up to 600 kW

Test System Defined according to CISPR and ISO standards • dedicated for component tests • dedicated for vehicle tests

Features Fixed Version

ated emissions (EMI): Full compliant according to CISPR 25 14. September 2016

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LOAD MACHINE FOR MOTOR TESTS (FIXED VERSION)

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Motor Test (fixed version)

8

4

5

7

3 2

1

6

Load Machine (Dyno) 2 Drive Unit Bench 3 CISPR 25 Test Table 4 Frankosorb® A2 Absorbers 1

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Frankonia Antenna Mast Vibration-free Basement 7 Shielded Room for Dyno 8 Anechoic Chamber (EDTC) 5 6

5

Motor Test (fixed version) - Features • • • • • • • • • • • •

Radiated Emission (EMI): Full compliant according to CISPR 25 Radiated Immunity (EMS): Full compliant according to ISO 11452-2 Load machine (dynamometer) available as a fixed version from 125 kW up to 350 kW Additional battery simulation up to 1.000 V, 350 kW and 600 A available Liquid or air cooling load machine Solutions for powertrain component or complete vehicle tests (full flexible use) Frankosorb® A2 non-combustible absorbers as a must have! Shielded-shaft, fully integrated in the Anechoic Chamber Highest European safety standards Integration kit for existing chambers available EMC knowledge-exchange base and worldwide service Turnkey solution by Frankonia

Load Machine Systems Version: *

EDTC-125

EDTC-160

EDTC-250

EDTC-350

Power range:

125 kW (both directions)

160 kW (both directions)

250 kW (both directions)

350 kW (both directions)

Revolution speed:

up to 6.500 RPM

up to 6.500 RPM

up to 6.500 RPM

up to 4.500 RPM

*other configurations available on request 14. September 2016

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Motor Test (fixed version) - Specifications EDTC Anechoic Chamber Dimensions:

Chamber requirements acc. to CISPR 25 (model ACTC, size: 7,88 x 5,33 x 4,05m), or integrated in CISPR 12 chamber (model AVTC or SAC)

Frequency range:

150 kHz to 18 GHz (40 GHz as option)

Measuring distance:

1,0m (typical)

Basement:

Vibration-free and non-interacting solid basement (floating slab or steel)

Absorber lining:

Frankonia Frankosorb® non-combustible DIN EN 13501-1 class A2 – s1 d0 absorbers acc. to CISPR 25 chamber requirements

Floor:

Highly conductive floor finishing and protection, integration of load machine fixation

EUT test table:

Test bench requirements acc. to CISPR 25 incl. drive unit bench and fixation set with shielded shaft for the external load machine

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LOAD MACHINE FOR MOTOR TESTS (MOBILE VERSION)

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Motor Test (mobile version) 1 2 3

4

4 5 6 7

8

8

Load Machine (BlueBox) CISPR 25 Test Table Contact strips Frankosorb® A2 Absorbers Connection Panel for EUT Connection Panel for BlueBox Turntable (additional) Ground Plane

1

3 2

5

6

7

Possible configuration of CISPR 25 test table and BlueBox

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Motor Test (mobile version) - Features • • • • • • • • • • • •

Radiated Emission (EMI): Full compliant according to CISPR 25 Radiated Immunity (EMS): Full compliant according to ISO 11452-2 Load machine (dynamometer) available as a mobile version from 32 kW up to 120 kW Additional battery simulation up to 1.000 V, 350 kW and 600 A available 360° EMC test with position on a turntable, or in combination with CISPR test table Solutions for powertrain component (full flexible use) Test setup preparation outside the EMC chamber possible, Plug&Play function Bulk body of BlueBox can be considered as a vehicle structure Highest European safety standards Integration kit for existing chambers available EMC knowledge-exchange base and worldwide service Turnkey solution by Frankonia

Load Machine Systems Version: *

BlueBox-32

BlueBox-40

BlueBox-63

BlueBox-120

Power range:

32 kW

40 kW

63 kW

120 kW

Torque:

82 Nm

130 Nm

240 Nm

470 Nm

Revolution speed:

up to 10.000 RPM

up to 7.000 RPM

up to 6.500 RPM

up to 6.000 RPM

*other configurations available on request 14. September 2016

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Motor Test (mobile version) - Setup Full flexible test setup with the Frankonia BlueBox: 1

Test setup beside CISPR 25 table, or

2

Test setup on a turntable with 360° test

Both test setups can be used for several test scenarios, and with any components or battery tests in combination.

2 1

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BATTERY SYSTEM

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Battery System - Introducing Scienlab Scienlab based in Bochum is specialized in Power Electronics and Electronic Testing Technology of innovative components in the automotive and industrial sector. Facing the challenge of electric mobility, Scienlab develops and produces efficient power electronics and integrated test system for: • Energy storages • Battery Management Systems • Fuel cell stacks and systems • Inverters • DC / DC converters • Chargers and charging infrastructure • and merger of several components.

nten des E-Antriebs testen

&

Battery System meets EMC Anechoic Chamber and Test System

Batterie

On-board charger

With the partnership of Scienlab, Frankonia offers adapted EMC test environments incl. EMC test equipment, and integrates Scienlab’s battery test system, DC emulator, and testing charging infrastructure in a turnkey solution. The Battery System includes modular packages: 1 Battery Test units from 100 kW up to 600 kW, and from 300 A to 600 A 2 Dynamic DC Emulators 3 Charging Infrastructure with Communication Modules (PLC, GB/T, CHAdeMO)

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Battery System - Features This Battery System typically offers a 1.000 V battery test system with the following options: • Operation as battery test system (=current source to test HV battery packs) • Operation as DC Emulator (=emulation of HV battery, e.g., to supply a traction inverter or machine) • Operation as DC quick charging station (=emulation of EVSE incl. communication) • Operation as AC charging station (with local grid, grid emulation excl.) • ChargingDiscoverySystem with EMC optimized casing • Fully adapted and integrated to Frankonia EMC Anechoic Chambers The communication between EV and EVSE will be done by the ChargingDiscoverySystem. With the options “PLC communication module” and “GB/T communication module” different charging standards can be tested. The battery system is tailored for Frankonia and for integration into an EMC anechoic chamber.

ChargingDiscoverySystem (CDS) Case 1: Analyzing communication between the EVSE and EV Case 2: Testing the charging function of a charging station (EVSE test) Case 3: Testing the charging function of electric/hybrid vehicles (EV test)

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This offer describes a 1000V Battery test system with the following options: ■ Operation as battery test system (= current source to test HV battery packs) ■ Operation als DC Emulator (= emulation of HV battery e.g. to supply a traction inverter or machine) ■ Operation as DC quick charging station (= emulation of EVSE, incl communication) ■ Operation as AC charging station (with local grid, grid emulation exkl.) ■ ChargingDiscoverySystem with EMC complaint casing The communication between EV and EVSE will be done by the ChargingDiscoverySystem.With the options “PLC communication module“ and “GB/T communication module“ can differtne charing standards be tested.

Battery System - Features Battery Test Systems

Besides this options are the following project efforts and services are offerd: ■ Transportation from Bochum to Heideck ■ Electrical installation of Scienlab test equipment ■ Engineering & validation for EMC optimization Output Voltage 300 A 600 A ■ Commissioning on side ■ final inspection on sideV 50… 1.000 Yes Yes

Power

Item

Size Cabinet

100 kW

SL1000/xxx/100DCE1C

2,4 x 2,8 x 0,8 m

125 kW

SL1000/xxx/125DCE1C

2,4 x 2,8 x 0,8 m

150 kW

SL1000/xxx/150DCE1C

2,4 x 2,8 x 0,8 m

180 kW

SL1000/xxx/180DCE1C

2,4 x 2,8 x 0,8 m

250 kW

SL1000/xxx/250DCE1C

2,4 x 3,6 x 0,8 m

350 kW

SL1000/xxx/350DCE1C

2,4 x 3,6 x 0,8 m

600 kW

SL1000/xxx/600DCE1C

2,4 x 7,2 x 0,8 m 002 Configurations

System Basics • Highest European safety standards • Integration kit for existing chambers available • EMC knowledge base and worldwide service • Project Management • Turnkey solution by Frankonia

50… 1.000 Vare not part of this offer Yes Yes by the cusThe following components and has to be provided tomer: 50… 1.000 V Yes Yes ■ DC EMC filter 600A ■ AC EMC filter 32...50A 50… 1.000 V Yes Yes ■ 1 pice. OptoConverter 1000MBit/s LAN 1.000 V (1x chamber wall, 1x Yes Yes ■ 2 pices50… LWL feed through HV casing) ■ Artificial network and all the cables from this components to the “HV module 50… 1.000 V No Yes EMC conform“ 50… 1.000 V

No

Yes

To following table shows the different possible configurations positions are concept is

System modularConfiguration Packages Configuration

Packet I

Packet II

Packet III

Battery test

x

x

x

Dynamic DC Emulator

-

x

x

Charging infrastructure

-

-

x

General & regional project realization

x

x

x

Service (according to region)

Opt.

Opt.

Opt.

Software maintenance*

Opt.

Opt.

Opt.

Table 1: Possible system configurations. * Contract directly between and end customer prefered.

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FRANKONIA ABSORBER TECHNOLOGY

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1

3 2

Frankosorb®

Frankonia Absorber Technology 14. September 2016

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Ferrite Absorber

2

Hybrid Absorber Pyramid Absorber

3

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EDTC and Frankosorb® Frankosorb® Absorber Technology • •

• • • • • • • • • • •

Nano thin-film technology guarantees highest homogeneity and impedance accuracy Non-combustible Absorbers according to DIN EN 13501-1 class A2 – s1 d0, equivalent to DIN 4102 class A2, and EN/ISO 5659-2 (smoke generation and opacity) >> our recommendation when performing EMC tests with battery or motor products Non-hygroscopic materials are used (humidity-proof and temperature-proof) Easy and modern installation style piece by piece that fits for any kind of shielding White coloring that improves the illumination level (no covers necessary) No dirt, no carbon dust, solvent-free, and free of glue or other harmful substances guarantees a healthy environment for people and EUT No aging or drooping, no loosing performance Lightweight absorbers require less statics Removable due to absorber fixation either by screw or hanging type Recyclable at 99% High-performance characteristics ensure reproducible test results Clean room classification according to ISO 14644-1 Class 5 Proven long-term stability for more than 25 years

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Thank you.

Your contact: Dr. Daniel Feyerlein FRANKONIA GmbH Industriestr. 16 | 91180 Heideck | Germany Office: Fax:

+49 9177 98 – 535 +49 9177 98 – 520

[email protected] www.frankoniagroup.com

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