The functional model for electric drives and HV systems in vehicles consists of a drive module and an energy supply and control module. The HV system works with an operating voltage of 96 V. It includes a complete energy supply unit with an electronic battery management system (BMS), an integrated charger for the HV battery, a control unit with an engine management system, all of the necessary safety components, a Mennekes charging connection and an extra robust service disconnect. The HV battery, with a nominal voltage of 96 V, is equipped with 32 LiFePO4/40 Ah cells. The battery management system features a Bluetooth interface. A corresponding app (Android) can be used to display the condition (voltage, temperature, balancing rate during the charging process) of each individual battery cell.
Drive ModuleThe drive module consists of a complete rear-axle powertrain with the gearbox from the Smart 450, 15 kW asynchronous motor, a control unit with controller (E-Car-Box), DC/DC converter, fuses, contactors and control software, and a hydraulic brake for load simulation (uphill driving).
E-Car-BoxThe E-Car-Box is the core element of the drive. It houses all key components for actuating the motor in a space-saving, secure and EMC-compliant manner; these are cabled in accordance with the most stringent safety standards. In addition to the air-cooled Curtis controller for actuating the motor, it also contains the main contactor, a DC/DC converter and all necessary high- and low-voltage fuses.
Battery Management System (BMS)The battery management system monitors the lithium iron phosphate battery cells installed in the HV trainer and the extent to which they are protected against overvoltage and undervoltage during the charging process and while driving. As such, the central control unit communicates with the connected charger and motor controller via CAN interface. The battery management system features a Bluetooth module for communication between the BMS and a display instrument such as a smartphone, tablet or Bluetooth-compatible Windows PC. Apps for Windows Mobile and Android are available for download. This module enables the state of charge of the batteries and various other parameters to be monitored.
Error circuits:
The training system has an integrated error circuit with which 10 errors in the power supply module and 16 errors in the drive module can be switched. The error circuit is controlled with a specially developed app (Android) via Bluetooth with a tablet or smartphone.
Executable work on the Christiani HV-Trainer:
Measurement capabilities:
