Electric test system

for automotive applicationsfor electric vehiclesfor electric motors

Overview
PC-controlled test system with a large insulated test cabin designed for stators and complete e-axles used in electric sports cars. The system supports fully automatic pre-series testing with automatic program selection via scanned DMC code.

Industry
Automotive industry / Electric motors

Challenge
Stators and complete e-axles must be verified for function and safety before installation. The test station must accommodate specimens ranging from small stators to full electric axles and enable complete pre-series test execution.

Solution
A test system with a double-leaf safety door and a fully insulated interior was developed. Test electronics and safety components are housed in a mobile 19" ESD test cabinet. Contacting is performed via test adapters with interfaces for winding and temperature sensors. Scanning the DMC code on the DUT selects the correct test program from the database; closing the door and pressing start launches the fully automatic sequence.

Functions / Key tests

• Ambient temperature measurement (and winding temperature if required)
• Winding resistance measurement with symmetry analysis and temperature compensation to 20 °C
• Resistance measurement of temperature sensors with temperature compensation to 20 °C
• Winding inductance measurement with symmetry analysis
• Insulation resistance test of the 3 phases versus housing
• High-voltage AC/DC test between the 3 phases and housing; freely adjustable ramp
• Surge testing including partial discharge measurement and rotor alignment
• Potential equalization measurement at up to 5 selectable points

Benefits

• Simple, intuitive operation for trained personnel
• Single connection of the DUT; full automatic execution of the test sequence
• Parameters and settings adjustable via software at any time
• Workplace safety compliant with EN 50191
• Large test cabin accepting complete e-axles including heavy/large assembly trolleys

Technical data / Specifications

• Surge test up to 6,000 V DC
• Partial discharge (PD) measurement during HV and surge tests, IEC-compliant PD measurement
• Insulation resistance test DC 100–6,000 V
• High-voltage AC test 100–5,500 V
• High-voltage DC test 100–6,000 V
• Temperature sensor for temperature compensation
• Internal dimensions (HxWxD): 2,000 x 1,600 x 1,800 mm
• Mobile 19" ESD test cabinet housing safety and test electronics