High speed test bench for electric traction drives

具有可调速度的电驱动器对于成功的能源转型至关重要。后者旨在实现从化石燃料到可再生能源的持续过渡。在交通部门，这尤其意味着用零排放车辆取代内燃机。无论再生产生的能量是存储在蓄电池中还是通过燃料气体中的电力到气体（power-to-gas），电力驱动（e-drive）将在未来的绝大多数交通工具中用作牵引驱动。其主要原因是在较宽的速度范围内具有高能效，以及电动驱动器可以实现的可观的功率密度。弗伦斯堡应用科学大学的研究小组“Innovative Antriebstechnik”（AG IA）成立于2020年，目前正在高速驱动领域开展多个研究项目。具体而言，正在研究使用新型磁性材料的电动汽车和柴电船舶的替代驱动概念。在此背景下，AG IA还研究了磁性材料的新制造工艺，这些工艺为未来几代电驱动器提供了全新的设计自由度。然而，到目前为止，还没有合适的设备可用于全面研究连接负载为50 kW至630 kW、转速高达25，000 rpm的三相电驱动器的稳态和瞬态运行特性。因此，研究人员无法独立地对其机器设计进行任何研究，这使得与应用相关的研究非常困难甚至不可能。本提案中申请的试验台旨在缩小这一差距，并加强目前的研究工作。它的成立还将继续促进与其他大学和行业合作伙伴的合作，以便未来计划的部分研究活动可以由第三方基金资助。大型研究设备包括一个具有恢复能力的电源电流转换器，一个为负载机供电的通用逆变器，一个沿着所需安全功能的机床，一个负载机和用于记录机械值的测量技术。该试验台的一个特点是，试样和载荷机直接以扭转刚性方式相互连接，无需插入齿轮箱。这缩短了传动系的轴向长度，降低了其惯性并避免了机械松弛。此外，通过这种新型的测试装置，还可以检查瞬态现象，这在优化具有多种负载变化的高速驱动系统方面发挥着重要作用。

Electrical drives with adjustable speed are of substantial importance for a successful energy transition. The latter aims to achieve a continuous transition from fossil fuels to regenerative energy. In the mobility sector, this means in particular the replacement of the internal combustion engine with zero-emission vehicles. Regardless of whether the regeneratively generated energy is stored in an accumulator or via power-to-gas in a fuel gas, an electric drive (e-drive) will be used as a traction drive in the vast majority of means of transport in the future. The main reasons for this are the high energy efficiency over a wide speed range paired with the considerable power density that can be achieved with electric drives. The research group “Innovative Antriebstechnik” (AG IA) at the University of Applied Sciences Flensburg, founded in 2020, is already working on several research projects within the field of high-speed drives. Specifically, alternative drive concepts for electric vehicles and diesel-electric ships that use novel magnetic materials are being investigated. In this context, the AG IA also examines new manufacturing processes for magnetic materials, which facilitate completely novel degrees of design freedom for future generations of electric drives. So far, however, there is no appropriate facility available for the comprehensive investigation of the stationary and transient operating behavior of electrical three-phase drives with a connected load of 50 kW to 630 kW at speeds of up to 25,000 rpm. Accordingly, the researchers cannot carry out any studies of their machine designs independently, which makes application-related research very difficult or even impossible. The test bench applied for in the present proposal is intended to close this gap and enable the enhancement of current research work. Its establishment will also continuously promote the cooperation with other universities and industry partners so that parts of the planned research activities can be financed by third-party funds in the future. The large-scale research equipment consists of a recovery capable mains current converter, a general-purpose inverter to supply the load machine, a machine bed along with the required safety features, a load machine and the measurement technology for recording the mechanical values. A special characteristic of the planned test stand is that the test specimen and the load machine are directly connected to one another in a torsionally rigid manner without an interposed gearbox. This shortens the axial length of the drive train, reduces its inertia and avoids mechanical slackness. Furthermore, with this new type of test setup, transient phenomena can also be examined, which play an important role in the optimization of high-speed drive systems with many load changes.