SESSION 2 – Electric Vehicle Powertrain Testing, Measurement and Analysis – HBK Technology Days 2022 Virtual Seminar Series
HBK Technology Days 2022 – Virtual Seminar Series
Session 2: Electric Vehicle Powertrain Testing, Measurement and Analysis
Testing electrical machines and electrical powertrains is a key task in developing the electric future of industry and transportation. To increase efficiency, acoustic quality, durability and reliability of next-generation electrical machines and drives, used in cars, other land vehicles, air vehicles and marine vehicles, requires testing with accuracy and precision, and analysis capability to characterise their steady state and dynamic operational conditions.
These presentations describe using electrical characteristics to identify motor degradation and failure, acoustic quality at end-of-line testing, efficiency characterisation by instantaneous power calculations.
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Understanding Motor Degradation and Failure modes using Electrical Characteristics
Mr. Mitch Marks, HBK, Electrification
Electric motors and powertrains present new challenges for durability testing and understanding the physics of failure. Traditional acceleration methods of running at an increased temperature are often not possible because the motor and inverter cannot survive them.
Motors also introduce new failure modes like demagnetization, delamination, and turn-to-turn shorts amongst others. These failures will result in mechanical failure modes but can be more easily monitored and understood through electrical measurements.
This session will discuss the failure modes of electric motors, the benefits of measuring electrical values for durability testing and give real data from durability testing.
Acoustic Quality Assurance in Industrial Production End-of-Line
Dr. Holger Behme-Jahns, Discom GmbH, Head of Project Engineering and Acoustics
Acoustical quality has become an increasingly important topic over the last few years. Customers expect technology to be not only reliable but also sustainable, well-designed and quiet. Especially in the automotive industry, the change toward electric mobility shifted customer expectations from roaring engine power sound to silent gliding. This leads to ever-increasing requirements for acoustic quality testing in production, not only in R&D.
A well-designed acoustic analysis for end-of-line testing can do much more than simply find “loud” units. By using constructive information about the device under test, irregular noises can be attributed to specific parts and root causes, enabling efficient repair. Combining results from actual drive tests in cars with limits derived from production statistics, it is possible to identify units which would lead to customer complaints and as well units which have hidden production defects. Long-term statistical analysis of production data expands the scope from the single device under test towards the whole production process with trends and hidden correlations.
This presentation will show the current state of end-of-line acoustic production testing with a focus on automotive powertrain applications and on the Discom production test system.
Instantaneous power calculations; active, reactive and apparent power, power factor and efficiency implications
Dr. Andrew Halfpenny, Director of Technology – HBK nCode Products
Do you struggle explaining the difference between ‘active’, ‘reactive’ and ‘apparent’ power, in a way that colleagues can understand?
Do they keep asking you why ‘phase-related reactive power’ should be separate from ‘frequency-related reactive power’?
Does your line manager understand why dynamic power analysis and optimisation of variable speed electrical machines used in EVs, is so much more complicated than constant speed machines used in a factory?
Would you like a nice story with pictures to replace pages of differential calculus?
If you are an Automotive or Mechanical Engineer who wants a conceptual understanding of dynamic AC power analysis, or an electrical engineer who wants a non-mathematical refresher, then this presentation is for you!
Free ONLINE Seminar - 90 minutes
November 8, 2022
10:00 am - 12:00 pm