High Voltage Integration Testbed: Tailored for BEV Development

Authors

M. Ivarson, Dr. P. Ebner, Dr. R. Luz, Dipl.-Ing. (FH) M. Walcher, AVL List GmbH, Graz

Year

2020

Print Info

Fortschritt-Berichte VDI, Reihe 12, Nr. 813

Summary

Development of future electrified powertrain systems (Battery Electrical Vehicles, Hybrids & PHEVs) requires significant adaptation of the development process, as well as the development environment. Testing of conventional, pure engine-based propulsion systems was fundamental to the development of conventional vehicles. However, the demands for future vehicles with electrified powertrains – with extended customer functions – requires a change in approach. A new and significant challenge is securing the integration of all HV components & control units of the vehicle.
This paper will introduce an integration approach specific to battery electric vehicles (BEVs), on a new type of testbed for HV systems. This new system is in principle, also compatible with all other types of electrified powertrains.
The challenge is driven by a significant change in the area of complexity of vehicles with electrified powertrains. In BEVs, the traditional functions (e.g. driving) get simpler and the environmental dependency of the powertrain (e.g. charging, connected powertrain functions …) get more complex. There are also significant changes in some pre-existing functions (e.g. power up).
These aspects are an opportunity to challenge and adapt the conventional testing approach and the related environments. One such environment is the powertrain testbed, where the complete powertrain and the required control units can be tested with dynamometers on each hub, before a prototype vehicle is available. Experience in several projects has shown that this particular environment, with a focus on being able to apply multiple dynamic torques, isn’t optimized for BEV development, and hence a new concept was developed. The HV-Integration testbed concept, leverages the high ratio of tests not requiring dynamometers for BEV development (i.e. where no torque needs to be applied) and therefore contains more simulation of environmental boundaries and residual-bus capabilities instead of vehicle driving simulation (dynamometers). The concept is optimized for integration testing, with a reduced cost, complexity and building requirements, compared to more conventional testbed environments.