Highly dynamic electric drive trains

Test benches must reproduce driving cycles as realistically as possible

Legislators are constantly demanding that vehicle manufacturers further reduce CO2 and pollutant emissions. In the long term, the aim is to achieve independence from fossil fuels. This is only made possible by electric drive trains and auxiliary units in the vehicles and by modifying vehicle components. This change requires high expenditures in the development area and drive train test benches with high dynamics, which make it possible to simulate electric drive trains with realistic driving cycles. But what is meant by highly dynamic? What is meant is the fastest possible regulation of the output voltages and low dips or overshoots with highly dynamic load jumps in the millisecond range or the ability to follow a high-frequency specified output characteristic curve precisely. Heinzinger ERS systems have exactly these characteristics. As well as the simulation of an ideal battery for electric drive trains, it is also possible to simulate the internal resistance of a real battery. Additional battery models for more complex requirements are integrated in the ERS system and are available as an option.

Safety on the test bench for electric drive trains takes top priority

In order to test electric drive trains, the safety requirements for the test benches are particularly high. Special training for handling high voltage is mandatory for test bench personnel. A high level of technical safety is decisively influenced by the selection of the right battery simulator for electric drive trains. Heinzinger ERS systems are equipped as standard with an insulation monitor and output relay in order to safely switch off the system’s high voltage from the test specimen in the event of a fault. With additional redundant output relays, even performance level D can be reached. Electric drive trains can still unintentionally feed voltage into the DC circuit on the test bench when switched off and therefore represent a potential source of danger. The optional active rapid discharge of the test specimen allows this danger to be reduced and safety on the test bench also to be increased.

More power when it counts

Short load peaks during acceleration and braking of the traction system are a typical phenomenon in an electric vehicle and a particular challenge for the on-board power supply. The battery can compensate for such load peaks, but what about a battery simulator? Electric drive trains determine the nominal power of the battery simulator in the test bench with the maximum peak power requirement, even if it is only needed for a few seconds. This can quickly become expensive.

The magic word for this problem is overload capacity. Due to their topology and robust design, Heinzinger ERS systems have a short-term overload capacity of up to 180 percent of the nominal output. With this feature, electric drive trains can be operated easily even with peak loads, and you get the same performance with a much smaller and above all cheaper battery simulator.

Are you testing electric drive trains for the automotive and electromobility sector? Then trust in the ERS series from Heinzinger and call us for more information on +49 8031 2458 0 or send an e-mail to info(at)heinzinger(dot)de.

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Would you like to know more about power supplies from Heinzinger?

The following products can be used for these applications

High voltage power supply up to 250kW

DC sources / sinks for testing rigs

Low voltage power supply - double stabilization and linear-control

Low-voltage power supplies with double-stabilization and linear-control

Compact low voltage power supply

GEN-Serie, Variable power supplies
Variable power supplies for integration into systems where space is scarce in the DC area