Electric Powertrain Component Testing

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******This proposal involves the development of a High Power High Frequency Emulation (HPHFE) test system for key components of electrified powertrains including battery packs, electric motors, and their control systems. The HPHFE would be the first of its kind because of its flexibility to shape and emulate signals in a synchronized form with high bandwidth and high power.******The transportation sector is going through a disruptive change. Internal combustion engines are being replaced or complemented by electric propulsion systems. Powertrains are evolving rapidly and there is a pressing need for infrastructure that would support research and development of electric powertrain components, namely electric motors, battery packs, and their control systems. Accurate and complete evaluation of electric motors and batteries is essential for the automotive industry and enables them to validate and improve computer models, perform competitive benchmarking, understand how these subsystems will interact with others in the vehicle (vehicle integration), and evaluate their performance under real world conditions, including faults. ******McMaster's Centre for Mechatronics and Hybrid Technologies (CMHT) has assembled state-of-the-art equipment for electrification research that include battery cell testing as well as electric motor dynamometer testing, and associated control instrumentation. The proposed High Power High Frequency Emulation (HPHFE) test system will be able to emulate 3 synchronized high-power signals with complete flexibility in terms of their current and voltage amplitudes with a high bandwidth. The HPHFE augments and completes CMHT's capabilities and has a functionality that is unique and does not exist in any other equipment. With this emulator, the CMHT centre will be able to provide a comprehensive environment for testing of any electric motor or battery pack within the common power and torque band of most electric passenger cars (from mild hybrids to full electric vehicles). It will allow development and testing to be conducted without the constraints of their control systems and the restrictions normally associated with controller hardware (speed, wave form, electrical switching, noise). As the emulator will have full control of the voltages and currents supplied to the motor or battery under test, it will provide advanced testing capabilities and power analysis in the high power/high frequency range of operation without requiring additional instrumentation with high fidelity. The HPHFE system's new capabilities for development and testing of electrified powertrain components is transformative for the strategically important automotive sector. **