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Transcript of 342n/ ì · 8Fþ FÜ + Fú>ô? G2G G^G GM0Û oGgG GOFþ6ä$Î
Development of HV Inverter Testing System Enable to Simulate Vehicle Behavior
Takahito Murata Tadashi Kobayashi Toshihisa Saito Hikaru Mizuno
We developed a HV inverter testing system which can simulate transient vehicle behavior without actual car, engine, transaxle and battery. This testing system became capable of various operating condition, for example wide-open-throttle acceleration, driving at very low speed and so on. It could also carry out a test of operating condition
difficult to be duplicated by experimental vehicle and realize various measurements. These results lead to remarkable man-hour reduction.
KEY WORDS: EV and HV system, power control unit, system technology, testing system (A3)
Advanced development Trial Manufacture Massproduction
Demands of adaptability test
Front loading of adaptability test to raise the design quality
Adaptability test with provisional samples
Marginal test beyond working limit
Mesurement while transient operation
Evaluation of mass-produced samples for next development
Fig.1 Ideal state of PCU experiment
Vol.45,No.3,May 2014. 521
技術論文 20144535
Development of HV Inverter Testing System Which Enables to Simulate Vehicle Behavior
522 自動車技術会論文集
実車走行時動作の模擬が可能なHVインバータ評価ベンチの開発
Table1 Driving conditions to simulate
Constant-speed runHigh-speed cruiseAcceleration with wide-open-throttleDeceleration with regenerationRepeat of acceleration and decelerationDriving at very low speedState in which wheels are stopped in spite of accelerator-onidling
Environmentaltest chamber
BTSILSBRS
voltage
Coolant
PCU : Power control unitILS : Inverter load simulatorBTS : Battery simulatorBRS : Battery internal resistance simulator
(for motor)
ILS(for generator)
resistance temp.flow
temp.humidityECU
command
Electronic load(for DCDC converter)
Electronic load(for air conditioner)
currentrevolution speedresolver angleelectrical constant
PCU
System controller
Fig.2 Overview of HV inverter testing system
Table2 Specification of ILS and BTS Maximum rated voltage 585Vrms
400Arms ( 400Hz)300Arms ( 600Hz)200Arms ( 1200Hz)
Frequency control range 0 1200HzMotor model Permanent magnet synchronous motorSystem construction 2 motors (for HV system)Frequency responsiveness 24min-1/msecResolver simulator accuracy F.S. 0.02%Voltage control range DC 100 600VMaximum rated output 200Adc (at 600Vdc)Voltage responsiveness 10V/msecCurrent responsiveness 2.1A/msec
ILSMaximum rated current
BTS
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PCUILS1
BTS
HV control device
Measurementcontroller
ILS2
Operationcontroller
Datastorage
Datastorage PC
Poweranalyze
Datalogger
1msec
4msec4msec
10msec50msec
Pattern file
Fig.3 Schematic diagram of command and measurement
BTSOperation controller
1msec
Controller
10msec
voltageHLS(SLAVE)
FL-net
ILS1Controller
HLS(SLAVE)
FL-net
ILS2Controller
HLS(SLAVE)
FL-net
HLS(MASTER)
HLS(MASTER)
HLS(MASTER)
Operating panelfor BTS and ILS
FL-net
revolution speedresolver angle
1msec
1msec
Fig.4 Communication method between machinery
0 5 10 15
Tor
que c
omm
and (
Nm
)
Revo
lutio
n spe
ed (r
/min
)
T ime (sec)
Command
Output
250
-1500
6000
Fig.5 Comparison between command and Output
ECU command
UVW
PN
resolver signal
detectedvoltage
Ed_fbEq_fb
Vd_com
Vq_com
Id Iq
--
Resolversimulator electrical angle
revolution speedresolver angle
Inductance (Lq,Ld)
coil resistance (R)
detectedcurrent
PCU
Outputreactor
convert todq-axis
InvertersinusoidalPWM
PIPIconvert to
dq-axis
voltagecommand
convert tothree phase
Motor voltage equationVd_com = R Lq Iq
Ld Id + R
--
++
Lout
Ed_com
Eq_com
Correction for outer reactorEd_com = Vd_com + Lout IqEq_com = Vq_com - Lout Id
Fig.6 Fundamental structure of ILS
524 自動車技術会論文集
実車走行時動作の模擬が可能なHVインバータ評価ベンチの開発
0 5 10 15 20
Out
put c
urre
nt (A
)
T ime (sec)
Id
Iq
After improvement
Out
put c
urre
nt (A
)
Id
Iq
Before improvement
Control failure
Vehicle
Testing system
250
-250250
-250
Fig.7 Improvement of output current by feedforward term
Lq (H)
Iq (A)
Id (A)
Fig.8 Lq variation with current
0 5 10 15 20
Out
put c
urre
nt (A
)
T ime (sec)
Id
Iq
Two-dimension Ld Lq table
Out
put c
urre
nt (A
)
Id
Iq
One-dimension Ld Lq table
Current fluctuation
250
-250250
-250
Fig.9 Improvement of output current by precise Lq and Ld
Lq profile from CAE
from actual vehicle data Back calculating plot
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Revolution speedResolver angle Transmit synchronously
0 r/min ?
Revolution speed
Resolver angleIntegration
Transmit to resolver simulator
Y
N
Fig.10 Command logic while very low-speed motor rotation
0
100
0
360
0 2 4 6 8 10 12
Revo
lutio
n spe
ed (r
/min
)
Reso
lver
angl
e (de
gree
)
T ime (sec)
Command
Output
Fig.11 Resolver angle comparison between command and output
voltage command
UVW
P
N
-
+
-
+
detectedvoltage
detectedcurrent
Chopper circuit
PI
dutycommand
PI
BRSPCU
Fig.12 Fundamental structure of BTS
0 5 10 15 20
Inpu
t vol
tage
(V)
T ime (sec)
260
160
Command
Output
Fig.13 Input voltage comparison between command and output
526 自動車技術会論文集
実車走行時動作の模擬が可能なHVインバータ評価ベンチの開発
0 5 10 15 20Time (sec)
Ris
e in
tem
pera
ture
of I
GB
T (
)
VehicleTesting system
±1
Fig.14 Rise in temperature of IGBT as wide-open throttle
Table 3 Experimental period shortening items using testing system
Need man-hour to exchange of only heat sinkPossible to experiment without cover and housingNeedless replacement and loading PCUNeedless preparation and restoration work for vehicleNeedless set-up for every PCU replacementNeedless vehicle set-up for measurementNeedless orientation drivePossible to experiment aloneShorter experimental working at repeatitive test
PCU set-up
Vehicle set-up
Measuringsystem set-up
Experiment
Testingsystem
Actualvehicle
test
Man-hour (Hr)
PCU set-up Vehicle set-up
Measuring system set-up
Experiment
800
Fig.15 Total reduction man-hour using testing system