Functional model of e-drives and HV systems in motor vehicles
The functional model E-drives and HV systems in motor vehicles consists of a drive module and a power supply and control module. The HV system operates with an operating voltage of 96 volts. A complete power supply unit with electronic battery management (BMS), an integrated charger for the HV battery, a control unit with motor management system, all necessary safety components, Mennekes charging connection (type 2) are built on. The HV system can be enabled either via a service disconnect in the 12 V circuit or via a service disconnect in the HV circuit (in the HV battery). In addition, the training system has a rescue disconnection point to represent the disconnection of an accident-damaged vehicle. The HV battery, with 96 volts nominal voltage, is equipped with 32 LiFePO4 / 40 Ah cells. The battery management system has a Bluetooth interface. The status (voltage, temperature, balancing rate during the charging process) of each individual battery cell can be displayed via an associated app (Android).
Drive modul
The drive module consists of a complete, vehicle-electric drive train with 1.6 kW asynchronous machine, control unit with controller (E-Car-Box), DC/DC converter, fuses, high-voltage main contactor and control software with multi-stage adjustable recuperation mode for displaying energy recovery as well as a hydraulic brake for load simulation (driving uphill).
E-Car-Box
The E-Car-Box is the heart of the drive. All important components for controlling the motor are installed in it in a space-saving, safe and EMC-compliant manner and wired according to the highest safety standards. In addition to the air-cooled Curtis controller for controlling the motor, it also contains the main contactor, a DC/DC converter and all the necessary high- and low-voltage fuses.
Battery Management System (BMS)
The battery management system is used to monitor the lithium iron phosphate battery cells installed in the HV-Trainer and to protect them from over- and undervoltage during the charging process and while driving. The central control unit communicates via CAN interface with the connected charger and the motor controller. The battery management system has a Bluetooth module for communication between the BMS and a display instrument such as a smartphone, tablet or a Bluetooth-enabled Windows PC. This module can be used to monitor the state of charge of the batteries and various other parameters. Software for Windows and an Android app are available for download.
Feasible work on the HV training system:
Measurement possibilities:
Fault circuits
The functional model has an integrated fault circuit with which 10 faults in the power supply module and 16 faults in the drive module can be switched. The fault circuit is controlled with a specially developed app (Android) via Bluetooth with a tablet or smartphone (included in the scope of delivery).
Fault circuit in the drive module:
Fault circuit in the battery module:
An accessory box with the following contents is supplied with the HV Trainer:
