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Integrating Engineering & IT Simulation, Automation and Control Solutions Enterprise /Domain Level Product Validation and Verification Management Solutions Test Lab Asset and Data Management Solutions Engineering Turnkey Testing Solutions Standard Products and Custom Projects Vehicle/Engine Testing Solutions Advanced / Special Test Rigs Driving Robot System Test Equipments Distributed Brix BRIX PVM BRIX DVP Scenario based Testing for ADAS & AD Brix Ontology Brix Label Brix Scenario Orbit E Orbit X Orbit eV Orbit Central Orbit V Brix Lite Brix Lab Distributed Brix iASYS PRODUCT LINE
EV Testing and Validation solutions
EV Validation Pyramid CONFIDENTIAL www.iasys.co.in info@iasys.co.in 1 2 3 4 5 6 On-Road Validation Vehicle Validation - Lab Level Power Train Validation - Test Bench Level Sub - System Level Validation Motor sub - system RESS sub - system Component Level Validation Element Level (Battery Specific) Cell Level Module Level Battery Pack Level Motor Motor Controller Battery Management System Battery VirtualValidation RealTimeValidation
EV Testing Solutions CONFIDENTIAL www.iasys.co.in info@iasys.co.in System Level Validation Sub System Validation Component Level Validation
System level Validation
Vehicle Chassis Dynamometer
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Vehicle
Acceleration test Motor characteristics test 30 minutes power test Efficiency
power
Legislative drive cycle WMTC and IDC Gradient simulation test Duty cycle from on road data
of test which can be performed in lab level, CONFIDENTIAL www.iasys.co.in info@iasys.co.in |
Level Testing and Validation Range test with Auto throttling robot.
test with
analyzer.
Type
Chassis Dyno Host & Drivers aid
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Vehicle Testing on chassis dyno as per AIS Standards Test Standards Motor Characterization test/ WOT Measurement of vehicle maximum power AIS 137 Consumption of electric energy/ range test Drive cycle test Acceleration test Gradient simulation test Efficiency test R&D test R & D Tests As per customer requirement if possible AIS 039 - Measurement of Electrical Energy Consumption & AIS 040 -Electric Power Train Vehicles Method of Measuring the Range Measurement of Net Power and 30 minutes power test AIS 041 - Electric Power Train Vehicles Measurement of Net Power and The Maximum 30 Minute Power Dyno simulates the load as per EPA Standard 40 CFR 1066 Dyno simulates the load as per EPA Standard 40 CFR 1066
Auto Throttling Robot
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Telematics/On road data platform
On road data can be recorded with some data loggers which relates to vehicle. Using the Log data, we can create different scenarios like driver, traffic behaviors etc.
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System Level Validation CONFIDENTIAL www.iasys.co.in info@iasys.co.in | Drivetrain/Powertrain Testing: Powertrain Testing of the vehicles along with the motor can be provided to the customer. All types of gearbox are tested with various gear ratios and torque values. Using the same Motor test bench with its own transmission helps to reduce the extra setup cost and efforts. 1. Performance, Emission & durability 2. Inertia Simulation range: 150 to 2500 kg 3. Maximum Speed: up to 200 km/h 4. Roller surface: Textured Coating as per EPA Compliance 5. Road load simulation: As per EPA 40 CFR Part 1066
Sub
SYSTEM LAYOUT for E-Axle
Dyno-1 Dyno-2
The system Consists of two oppositely mounted load machines connected to the output shafts from the e-Drive unit being evaluated.
High specification permanent magnet synchronous electric motors are used to replicate the loads applied by the driven wheels.
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E-Axle configuration CONFIDENTIAL www.iasys.co.in info@iasys.co.in | Parameters Range (Min to Max) Power (kW ) 30-250 700-8900 200-2400 800-550 Rated Continuous torque at wheel (Nm) Max input torque (Nm) Max speed at wheel (RPM ) Current (Amp) Voltage (V) 450-700 250-750
Component Level Testing and Validation
The component-level testing includes
Motor
Testing
Motor Controller Testing Battery Testing
Along with the individual component testing these components can be tested with vehicle level Simulation also. How each component will behave on vehicle level can be simulated.
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EV Motor Testing CONFIDENTIAL www.iasys.co.in info@iasys.co.in Transient Motor Dynamometer: Transient motor dyno set up to test various types of electric EV motors used in all automotive applications from 2W, 3W, 4W & commercial vehicles. Road load simulation is carried out on motor level testing to get on road test data in component level testing. Various supporting devices such as DC power supply, Power analyzer, Current sensors helps these testings to get accurate technical data 1. We provide portable Containerized EV motor Test bench 2. Overall System sampling rate 20Hz & more 3. Accuracy upto 0.03% 4. Regenerative Bi-directional power supply 80 V, 420 amp 5. Upto 8 Channel power analyzer with accuracy 0.03% 6. Testing standards: ISO 2178, AIS 38, AIS 39
By adding vehicle level road load data as an input, simulation of real road load conditions can be performed on the motor.
This will ensure how well the motor will perform on the field. Environment simulation can also be done to simulate real-time physical changes on the motor as well such as temperature.
Vehicle Simulation at Motor Level 0 500 1000 1500 2000 2500 3000 0 5 10 15 20 25 30 35 40 1 1 6 3 1 4 6 6 1 7 6 9 1 1 0 6 1 2 1 1 3 6 1 5 1 1 6 6 1 8 1 1 9 6 2 1 1 2 2 6 2 4 1 2 5 6 2 7 1 2 8 6 3 0 1 3 1 6 3 3 1 3 4 6 3 6 1 3 7 6 3 9 1 4 0 6 4 2 1 4 3 6 4 5 1 4 6 6 4 8 1 4 9 6 5 1 1 Demand Speed and Demand Torque Torque_Demand(NM) Speed_Demand(RPM)
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Motor Testing as per ISO standards CONFIDENTIAL www.iasys.co.in info@iasys.co.in | Type of Test Standards Measurement of total loss and total efficiency ISO 21782-2:2019 ISO 21782-2:2019 ISO 21782-2:2019 ISO 21782-6:2019 ISO 21782-6:2019 ISO 21782-6:2019 R&D test As per customer requirement if possible Temperature rise test 30 minutes power test Torque characteristic Test High acceleration/deceleration endurance Test Maximum Torque Endurance Test Overspeed Test No Load induced EMF R & D Tests
E-Motor Testing
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Battery Testing
Testing solutions for batteries ranging from 2W to commercial applications can be provided. EV battery testing equipment is equiped with latest technology available in the market. We provide testing solutions ranging from 2kWh to 100kWh battery packs. The tests are performed by following various standards like USABC, ISO12405, AIS 048 etc. With the growing realization of the importance of the battery safety, our EV Battery solutions is completely safe and compliant to the standards like ISO26262, EUCAR, etc.
Some of the tests performed are:
1.Battery peak power test
2.Constant current discharge test
3.Partial discharge test
4.Overcharge test
5.Drive cycle tests
6.Customized tests
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Vehicle Simulation at Battery Level
Voltage and Current Urms1(V) Irms1(A)
Simulation of battery charge & discharge pattern using bidirectinal power can be performed. Power source which is coupled with battery will act as a source and sink, based on the program created for the battery cycle simulation.
0.00 10.00 20.00 30 00 40.00 50 00 60.00 70.00 1 2 9 5 7 8 5 1 1 3 1 4 1 1 6 9 1 9 7 2 2 5 2 5 3 2 8 1 3 0 9 3 3 7 3 6 5 3 9 3 4 2 1 4 4 9 4 7 7 5 0 5 5 3 3 5 6 1 5 8 9 6 1 7 6 4 5 6 7 3 7 0 1 7 2 9 7 5 7 7 8 5 8 1 3 8 4 1 8 6 9 8 9 7
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Our Engineering R&D Center (Vehicle Testing on Chassis Dyno)
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Our Engineering R&D Center ( Engine Testing)
Container Test Cell Solution For EV Motor Testing
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Our Esteemed Customers Commercial Educational & Govt.Organizations Components Engines Farm Equipment Passenger Car Two Wheeler EV Certification & Testing Lab
iASYS, Products DVP SMART VALIDATION (ENTERPRISE LEVEL) SMART TEST CELLS SMART TEST PROCESSES SMART TEST LAB SMART TEST DATA remote lite distributed CONFIDENTIAL www.iasys.co.in info@iasys.co.in |
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