ELECTRICAL/HYBRID VEHICLE TEST

Expert Workshop on

Testing of Electric Vehicle Performance and Safety PoliMi Expertise on On-Road Vehicle Test

Prof. Federico Cheli – Ing. Davide Tarsitano

Looking forward to the Milestone 2 (2016) of European Roadmap Eletrification of Road Transport In order to allow the adoption of advanced system integration and high performance energy storage systems for improving efficiency on the 2nd generation of electric vehicle, a broaden testing phase must be foreseen. This phase needs to consider all the matters involved in a new vehicle design and test:

Vehicle Tests Ad hoc experimental set up for: •  HEV/FEV/PHEV power train and storage monitoring and efficiency

measurement •  ABS/ESP performance for safety purpose

BATTERY/SUPERCAPACITOR TEST RIG

Battery test rigs have been developed for testing cell performances. In Tab.1 the main performances are described.

BATTERY CHARGER Battery charging and drive chain testing in laboratory

POWER TRAIN TEST RIG

Test Rig Technical Data Maximum Discharge Current 300 A

Maximum Charge Current 300 A

Maximum Battery Temperature 70 °C

Minimum Battery Temperature 5 °C

Tab.1 Test Rig Technical Data

Test Bench main components: •  Battery/Supercapacitor under test; •  DSP based board both for data

acquisition and for power electronic management

•  Programmable Power Supply •  Data Acquisition System and Test control

device on PC

The aim of this test rig is to identify the tank-to-wheel performances of an electric vehicle power train composed by:

Fig. 6 100 kW Power Train Test Rig

•  Batteries

•  Inverter

•  Motor

•  Gearbox

•  Differential Gear

•  Mechanical brakes

The test rig has a flexible structure for testing different hybrid power train architectures (series/parallel) and it works both in motor and in braking (regenerative) conditions

The power train test rig is composed by:

Vehicle Control Unit Design

•  Vehicle Control Unit for power train control and energy management •  Analog and Digital I/O, CAN communication •  DSP based board •  Suitable for the implementation of algorithms both for hybrid power train and

hybrid storage systems

Fig.2 Handling Performances Tests Fig.1 Electric Vehicle Consumption Tests

Fig.3 Vehicle Control Unit Design Fig. 5 Test Rig Results (60 Ah Battery)

Fig. 4 Battery Test Rig

MC's PlotXY - Fourier chart(s). Copying date: 01/03/2008File 4Q_interallacciati_con_transitorio.pl4 Variable c:Q1IN -Q1OUT [|pu of harm. 1|]Initial Time: 0,23 Final Time: 0,25

0 10 20 30 40 500,0

0,2

0,4

0,6

0,8

1,0

harmonic order

Experimental results and power quality analysis of voltages and currents

Fig. 7 Battery Charger Fig. 8 Drive Chain

Fig. 9 Power Quality Analysis

•  1 controlled AC induction motor Motor Continous Power: 100 kW Motor Continous Torque: 500 Nm

•  2 controlled Eddy current brakes up to 750 Nm each dynamometric cradle

•  Ligth frame •  Dinamical behavior of the vehicle •  Re design of ABS/ESP algorithms

•  Safety in case of crash •  Efficiency of the whole power train •  Charging infrastructure

Contacts: prof. Federico Cheli -> federico.cheli@polimi.it +39 02 2399 8462 Contacts: ing. Davide Tarsitano -> davide.tarsitano@polimi.it +39 02 2399 8378