High speed test bench for electric traction drives

速度可调的电力驱动对于成功的能源转换是非常重要的。后者的目标是实现从化石燃料到可再生能源的持续过渡。在机动部门，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储存在蓄电池中，还是通过燃气中的电力转化为天然气，电驱动(e-Drive)将在未来的绝大多数交通工具中用作牵引驱动。其主要原因是在很宽的速度范围内具有很高的能效，同时电力驱动可以获得相当大的功率密度。弗伦斯堡应用科学大学成立于2020年的研究小组“Innovative Antriebstechnik”(AG IA)已经在从事高速驱动器领域的几个研究项目。具体地说，正在研究使用新型磁性材料的电动汽车和柴油-电动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气驱动器提供了全新的设计自由度。然而，到目前为止，还没有合适的设备来全面研究连接负载为50 kW到630 kW、转速高达25,000 rpm的三相电动传动的静态和暂态运行行为。因此，研究人员无法独立进行任何关于他们的机器设计的研究，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。它的成立还将不断促进与其他大学和行业合作伙伴的合作，以便未来计划中的部分研究活动可以由第三方资金提供资金。大型研究设备包括一个可恢复的电源电流转换器、一个为负载机供电的通用逆变器、一个具有所需安全功能的机床、一个负载机和记录机械值的测量技术。计划中的试验台的一个特殊特点是，试件和加载机以扭转刚性的方式彼此直接连接，而不需要插入变速箱。这缩短了传动系的轴向长度，减小了其惯性，并避免了机械松弛。此外，利用这种新型的测试设置，还可以检查瞬变现象，这在负载变化较多的高速驱动系统的优化中发挥着重要作用。

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.