Many industries are now being required to drastically reduce carbon emissions as a consequence of rising global temperatures, and the automotive industry in particular is a focus of much regulatory pressure.
Fundamental to the need for original equipment manufacturers to meet the rigorous safety requirements of an entirely new generation of electric vehicles is the ability to implement repeatable quality testing using the most advanced technology in test rigs.
The Electric Vehicle (EV) market now needs specially-adapted high-speed motors for test benches that will offer sufficient speed, power and acceleration to meet the tough qualification process for electric engines, pumps and powertrain transmissions. Over the past few years, Parker has received numerous requests for test rig motor speeds above 22,000 rpm, with torque levels above 400 Nm and high dynamic performance. This has led Parker to develop a new high-speed MGVA motor to extend the MGV series of brushless synchronous servomotors with, which features water cooling and electromagnetic optimisation to offer increased service lifetimes, reduced maintenance and optimum performance to meet market expectations.
Typically, any high-speed application will require a specialist integrator who will design the test rig system, looking for the right combination of products that will endure the rigours of the test campaign. This expert will need to decide on all the various mechanical factors of the system, such as ensuring the correct dimensions and rigidity of the test bench chassis to avoid resonance-relation vibration, choosing the best type of coupling according to the line shaft, speed, torque and acceleration, and ensuring that the temperature is controlled to avoid failure.
After this is complete, the specialist integrator will need to find an appropriate drive solution for controlling the MVGA servomotor, such as the Parker A30 drive. Above nominal speeds, the permanent magnet AC motor will need to be controlled under a ‘field weakening’ mode to protect the rig from overvoltage in case the power supply goes down.
A turnkey cabinet will then need to be built to enclose the rig. The cabinet should provide overvoltage protection and a four-quadrant active front end (AFE) solution if necessary, depending on the particulars of the test cycle. To complete the project, a water chiller is then installed for precision cooling.
Parker can provide custom solutions tailored to meet even the most challenging technical specifications. The expertise of our technology-focused engineering team allows the OEM to decide how much or how little support they need. Parker’s extensive portfolio, which includes motors, drives, controllers, HMIs, actuators and gearheads ensure the right combination of application-compatible products will be selected every time.
The high-speed electric vehicle test bench plays a vital role towards ensuring the safety and performance of vehicle electrification, which in turn will allow us all to enjoy cleaner air free of fine particles in the future.
Article contributed by Jean-Philippe Olry, application engineer industrial market, Electromechanical & Drives Division Europe, Parker Hannifin Corporation.