the challenges of e-drive & its validation

0

The Challenges of e-Drive & Its Validation

William Chang

Chroma ATE Inc.

2019/6

E: [email protected] W: www.chromaate.com

1 iEVTech 2019, EVAT

Agenda

1. Technology in e-Drive

2. Validation Requirement

3. Validation Tool

4. Conclusion


e-Drive Configuration

Battery Motor Gearbox MCU

(Inverter)

DC/DC

OBC

BDU

EVSE

Electric Drive Configuration

Ju

nctio

n

Bo

x

BMS

Power Electronics Mechanical Parts


e-Drive Design Criteria

Reliability & Safety

•Protection

•Component Quality

•Validation & Safety Compliance


EV Power Electronics Technology Index

Design Target Index

• DSP-based Control

• Intelligent Drive Control Circuitry

• Cooling System

• Regenerative Braking

• CAN-bus Interface

• Advance Power Protections

• Light Design (20kW/kg)

• High Power Density Design (20kW/L)

• Quick Response (100ms)

• High Efficient Cooling (150W/cm2)

• High Reliability (>15 years, >150K km)


V-model of Automotive Product Development Le

vel o

f In

tegr

atio

n

Requirements

Design & Simulation

Sales & Aftermarket

Testing & Validation

Integration & Implementation

Level of Maturity

Component/Part

System

Vehicle

Verification & Validation


Thermal Design (V-System Level)

Heat Dissipation Design & Simulation


Force Stress Analysis (V-Component Level)

Integration & Vibration Verification

656Hz

Frequency (Hz) Power Spectral

Density

10 20

55 6.5

180 0.25

300 0.25

360 0.14

1000 0.14


Verification (V-System Level)

Function Test

1. DC Bus leakage current Test

2. HV over voltage protection

3. Contact resistance Test

4. Thermal protection Test

5. Rated/peak current Test

6. LV under voltage Test

7. Burn-In Test

8. Hi-Pot Test (2000Vac, <1mA)

9. Insulation resistance (600VDC,>10Mohm)

10. No load 1000rpm Test

11. Motor lock test

12. Dynamometer test

Auto Testing Equipment (by Chroma) 1000A by pulse/500A 30sec

Support MES Interface.

Report analysis

Auto Testing


Elaboration Phase - SW Development Safety

AUTomotive Open System ARchitecture.

Application Software

Hardware

Application Software

Hardware

Standardized

HW-Specific

Using standards -Communication Stack

-Diagnostics

-CAN

Customer Needs -Adaptive Cruise Control

…

Ref : Rebeca D.” AUTOSAR software Overview” ., Sep. 2017


ISG Controller Battery

BMS Inverter

DC/DC

BDU

OBC

EV Power Electronics

Battery Disconnect Unit

EREV ISG Controller

Battery Management System

Motor Controller (Low Voltage )

BEV Motor Control Unit PHEV Motor Control Unit

Jun

ction

b

ox


eAxle

3-in-1 Two speeds electric drive system


Motor Control Unit (Inverter)

20kW 40kW 60kW 80kW 100kW Continuous Power

200kW

Peak Power

150kW

100kW

50kW 40/25kW

80/35kW

180/70kW

105/45kW

150/60kW

LSEV

Passenger Car

SUV/Commercial

Performance/Minibus

200/90kW


Power Electronics Module (PEM) for Tesla Roadster

Optimized manufacturability and reliability

EOL test by Chroma ATS

0% IQC failure with 5000+ units shipped

Customization satisfaction

2007


Inverter & BMS for Passenger EV

S3 EV+

SOP：2017, Q4

LUXGEN S3 EV+ Specification

Acceleration (0~100kph) 7.2sec

Speed 147 km/h

Continuous Power 45kW

Peak Power 150kW

Climb > 34%

Energy Consumption EV : ~ 130Wh/km

Driving Range BEV: 220 km

Motor Control Unit BMS

+

https://www.google.com.tw/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiN7vmyt-jNAhWLGJQKHTLrAXcQjRwIBw&url=https://c.8891.com.tw/photoArt-article.html?id=3039&psig=AFQjCNGb1v-5PJB5AXEWHOacRG-ukTTS8A&ust=1468224115917097

http://www.google.com.tw/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwj9-cOQuujNAhVHNpQKHbtGCE0QjRwIBw&url=http://mbistw.blogspot.com/2012/06/luxgen.html&psig=AFQjCNGnx3TOxU0i8Sm10_vgs_dh0i4FQQ&ust=1468224896175440


Dual-mode Motor Control Unit for PHEV

插電式混合動力新能源車

SUV

SUV Specification

Acceleration (0~100kph) ~ 11.4 sec

Speed 147 km/h

Driving Motor Peak Power 105kW

ISG Peak Power 47kW

Climb > 34%

4 Modes BEV、Regen、Acc.、High Speed

Driving Mode Driving Mode BEV

Energy Consumption Energy

Consumption ~ 206Wh/km

Driving Range Driving Range 55 km

Dual Mode MCU


Low Voltage Motor Controller

Features: Applicable for IM, PM, BLDC motor

Auto-learning motor control algorism

MPTA function for extra torque

High power density & efficiency

Compact size for easy installation

Application \ Model CR10 CR15

e-Scooter ●

e-Motocycle ● ●

Micro EV ●

eTruck ●

eForklift ● ●

UTV ● ●

ATV ● ●

Sightseeing Car ● ●

eJeepney ●

eTrike/3W ●

Golf car ●

Go-Kart ●


SMARTuning® Software


New Technology & Its Risk

Is new EV technology really safe


xEV Safety Requirements

EV Safety

Vehicle Safety

Driving & Comfort

Motor

Power Electronics

Battery

Charging Station

Collision safety Electric safety Network safety

Dynamic performance Power consumption Driving range

Performance Environment test Electric Safety

Electric safety Regulation compliance Interoperability

Charge & discharge Real-time monitoring Auto protection

Performance Environment test Protection & Reliability


Verification for EV Drivetrain Component

What testing equipment are available?


Electrical Vehicle Test Solutions

BMS PCBA ATS HCU(VMS/VCU)

ATS

Battery Pack

ATS

Regenerative Battery

Module/Pack

Test System

Charger Station (EVSE) ATS

Electrical Safety

Analyzer

DC-DC Converter

ATS

AC Charging

Compatibility ATS

Regenerative

Battery Cell Test

System

Motor Stator

Test System

Wireless Charger ATS


Power Electronics Unit/Inverter & Board Level ATS

Traction (Motor) Driver Open Loop Test: components, circuit, temperature test.

Control board Driving board


OBC & DC-DC Converter Test Solution

- Built standard test items, meet GB/T & QC/T test requirement, CAN

communication included. Suitable for Certification Lab & Production Line.

中国汽车技术研究中心

法雷奥

The rights of above referenced trademarks belong to each registered company.


AC/DC EVSE(Electric Vehicle Supply Equipment) Test Solution

- Meet IEC/SAE/GB/CHAdeMO…etc test requirements cover the EV charging

regulation worldwide & provide standard test items

中国汽车技术研究中心


http://www.google.com/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=2ahUKEwibn4ff6c3bAhWE7Z8KHTTlD5gQjRx6BAgBEAU&url=http://www.myir-tech.com/product/my_evc6200.htm&psig=AOvVaw0o_FiggAQi3ND6eiaZa2Jp&ust=1528882595208723


New

EV Wireless Power Transfer(WPT) Test System

- Meet SAE & GB/T test requirement, include

• Eff. & Misalign. Coefficient

• Magnetic Field

• Surface Temperature / FOD Test

XYZ Positioning Device



EV Drivetrain Test : Dynamometer

Power: 250kW,

Speed: 15,000 rpm

Torque: 500 Nm MCU (Driver) Motor

HIL (hardware-in-loop)


Automotive Electric Safety Test Solution

联合汽车电子大陆汽车

德尔福博世电子

特斯拉(美国)



Battery Test & Automation Solutions

Cell Formation

Module/Pack

Cell Reliability Test

HT Aging

Barcode

Binding

Formation Grouping

OCV & ACR Test

RT Aging

Applications

Battery cell semi-finished product

Battery cell

Super capacitor

Battery management system

Battery module

Battery pack

Battery Cell Automated Test Systems

Battery Cell Insulation Tester

Battery Cell Barcode Binding Equipment

Regenerative Battery Cell Formation System

Battery Cell OCV & ACR Test Equipment

Battery Cell Grouping Equipment

Battery Charge/Discharge Test System

Battery Module/Pack Automated Test Systems

Battery Cell Simulator

BMS PCBA ATS

Battery Module/Pack Functional ATS

Regenerative Battery Module/Pack Test System

Battery Module/Pack ATS

Battery Module/Pack Maintenance ATS


Battery Pack Test Solution

17040 60KW – 300KW ,

Max: 1000V

17030 above 300kW/ 1500V

17020 5KW – 60KW

Max: 500V

- Charge and Discharge Test System


HIL (hardware-in-loop) Test Solution

Battery Pack HIL Dyno for Powertrain HIL Other HV Testbed HIL


Take Away…

1. For EV power electronics, power density, performance, cost, and reliability are

important, among them, the safety is utmost critical.

2. Unlike gasoline cars, xEV technologies are still new and lack of long-term

safety validation record.

3. To identify potential risks and error through continuous effort of testing and

validation.

4. Automatic test system can not only increase the test item coverage and

speedup the R&D process in EV component developing stage, but also

conduct end-of-line test in the mass production stage to ensure the

performance and quality of the products.

The devil is hidden in the details.

32

About Chroma ATE Inc.


Company Profile

Founded 1984.11.8

Paid-up Capital US $138.9 Million

IPO 1996.12 (TAIEX : 2360)

Chairman & CEO Leo Huang

Employees Global 2,444; Taiwan 1,716 (2019.01)

Revenue US $ 251.6 Million (2018)

US $ 564.4 Million (2018 Consolidated,)

Headquarter Taoyuan, Taiwan

Products: Test & Measurement Instruments

Automated Test Systems

Intelligent Manufacturing Systems

Test & Automation Turnkey Solutions

Harvard Business Review

The Taiwan Top 50 Best Performing

CEO, 2018 (Ranked No. 14)


Vision & Mission

Chroma provides test & automation turnkey solutions for customers

to ensure the performance and quality of their products.

◆ Precision

◆ Reliability

◆ Uniqueness

World-class Products World-class Enterprise

◆ Innovative Technology

◆ “Chroma” Brand

◆ Globalization


Global Operation Sites

48 Operation

Sites

96 Distributors

Netherlands:

Ede

Quantel：Singapore

Taiwan: Taoyuan (Headquarters)

EST. 1993 EST. 2001 EST. 1999 EST. 2017

EST. 2016

EST. 2003

Japan:

Shin-Yokohama/

Nagoya/ Osaka

EST. 2008

Korea:

Pangyo

China/ Xiamen China/ Chongqing

EST. 2011 EST. 2011

EST. 2018

United States:

Irvine, CA

Santa Clara, CA

Chandler, AZ

Allentown, PA

Albany, NY

United States:

Foothill Ranch, CA

Marlborough, MA

Detroit, MI

Mexico：

Ciudad Juarez

Others: Qingdao/ Zhengzhou/ Xian/Hefei/ Chengdu/ Wuhan/ Hangzhou/ Changsha/ Guangzhou/ Hong Kong

Germany:

Augsburg

Others:

India: New Delhi/ Mumbai/ Bangalore

Thailand: Bangkok

Vietnam: Hanoi/ Ho Chi Minh

Malaysia: Kuala Lumpur/ Penang

Philippines: Manila/ Cebu

Indonesia: Jakartar

EST. 2009 EST. 1998

China/ Shenzhen

EST. 2006

China/ Suzhou

EST. 2000

China/ Shanghai

EST. 1999

China/ Beijing

EST. 2001

China/ Dongguan

Taiwan: Hsinchu Taiwan: Kaohsiung


Production Base

Headquarters &

Taoyuan Factory

Kaohsiung Factory New Headquarters &

Taoyuan Factory

55,667 m2

Production Line:

AI Line, SMT Line,

PCBA Line,

Module Line,

Instrument & ATS

Assembly Line,

Mechatronics System Line

13,469 m2

Production Line:

Mechatronics System Line

104,141 m2

(2020.1H)

ISO 9001/9002

IATF 16949:2016

ISO/IEC 17025

ISO 13485


FPD/ Video & Color

Power Electronics

Passive Component & Electrical

Safety

Semi- conductor

/ IC

LED/ Lighting

Photovoltaic

Electric Vehicle

Battery

IMS & AI

Photonics & AOI

Product Mix

Automation

Integration

Test &

Measurement

IMS


Test & Automation Turnkey Solutions

• Test Instruments

• Automated Test Systems

• Turnkey Solutions

解決方案

40 Product Lines

618+ Models


Research & Development

0

50

100

150

200

250

300

2014 2015 2016 2017 2018

25.2 26.1 31.2 36.2 38.1

171.2 151.3

241.1

267.3 251.6

R&D Expenditure

Revenue R&D Expenditure

US$ Million

14.7% 17.3% 13.0% 13.5% 15.1%

Employee Distribution

(by Function)

R&D Expenditure/

Revenue

R&D

MFG

SALES

MGMT

125

414

444

684

40%

QC 49

Total

1,716


Technology Accomplishments

100 891

Core Technologies Patents, Worldwide

515

Patents, Taiwan

• Top 100 in overall rankings

• Ranked No.1 in Test & Measurement

industry


Customer Satisfaction

The rights of above referenced trademarks belong to each registered company

http://www.canadiansolar.com/

the challenges of e-drive & its validation

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