#ev testing

Tata Technologies (NSE: TATATECH), a global product engineering and digital services company, has entered into a strategic partnership with Emerson (NYSE: EMR), a global leader in industrial automation, to co-develop cutting-edge testing and validation solutions for next-generation vehicles. The collaboration aims to support global OEMs across automotive, aerospace, and commercial vehicle…

In an era where environmental concerns and technological advancements are at the forefront of global conversations, the rise of Electric Vehicles (EVs) represents a significant stride toward a sustainable future. However, behind the scenes of these eco-friendly marvels lies a pivotal process that ensures their viability, safety, and efficiency in EV testing.

1. Pioneering Sustainable Transportation:

The transition from traditional internal combustion engine (ICE) vehicles to EVs is an embodiment of sustainable innovation. EVs promise reduced carbon emissions, improved air quality, and decreased dependence on fossil fuels. However, to truly harness these benefits, rigorous testing is imperative. Testing validates the performance claims of EVs, substantiates their eco-friendliness, and bolsters consumer confidence in adopting these new modes of transportation.

2. Enhancing Vehicle Performance:

EV testing is not merely a formality but a process that can significantly enhance vehicle performance. Through meticulous testing, manufacturers fine-tune elements such as battery efficiency, power delivery, and regenerative braking. This optimization not only extends the range of EVs but also refines their responsiveness, making them a practical choice for consumers who seek both environmental responsibility and a satisfying driving experience.

3. Ensuring Safety and Reliability:

Safety stands as a paramount concern in any vehicle, and EVs are no exception. The intricate nature of electric propulsion systems demands thorough testing to mitigate potential hazards. From battery thermal management to charging circuitry, every component must undergo rigorous assessments to guarantee operational safety and protect drivers, passengers, and pedestrians alike. Moreover, exhaustive testing enhances the reliability of EVs, establishing them as a dependable mode of transportation in the long run.

4. Battery Performance and Durability:

The heart of an EV lies in its battery. Battery technology has made significant strides, but challenges like capacity retention, charging speed, and lifespan persist. Rigorous testing regimes simulate various conditions to assess battery performance under extremes of temperature, differing charging rates, and prolonged usage. By subjecting batteries to these tests, manufacturers can refine battery chemistry, thermal management systems, and charging protocols, resulting in more robust and durable batteries.

5. Accelerating Technological Advancements:

The process of EV testing is a catalyst for technological evolution. As manufacturers continually strive to improve EV performance, efficiency, and safety, the insights gained from testing feedback into the iterative design process. This feedback loop drives innovations in materials, manufacturing techniques, and software, contributing to the overall advancement of the EV industry and its ancillary technologies.

6. Regulatory Compliance and Standardization:

Regulatory bodies globally impose stringent standards to ensure vehicle safety and environmental impact. EV testing plays a pivotal role in achieving regulatory compliance. Through comprehensive testing, manufacturers validate their vehicles against these standards, contributing to a safer and more consistent market. Additionally, standardized testing protocols help level the playing field, enabling consumers to make informed comparisons between different EV models.

7. Real-World Performance Validation:

The transition to EVs involves a paradigm shift in how we perceive transportation. Real-world conditions vary significantly, and EVs must prove their mettle in diverse scenarios. EV testing includes driving simulations that replicate city commutes, highway journeys, and off-road adventures. These tests not only verify range claims but also provide manufacturers with insights into how their vehicles perform in different environments, enabling them to address potential issues and optimize user experiences.

8. Building Consumer Confidence:

For EV adoption to become mainstream, consumers need to have confidence in the technology. The thorough testing of EVs, backed by tangible data and real-world simulations, builds trust among potential buyers. Consumers can rest assured that their investment in an EV is backed by scientific validation and engineering excellence, further encouraging the shift away from conventional vehicles.

 Conclusion

 The importance of EV testing cannot be overstated. It serves as the bedrock upon which the entire EV ecosystem is built. From performance optimization to safety assurance, from regulatory compliance to driving innovation, EV testing is the crucible that refines these revolutionary vehicles. As our world pivots towards sustainability, the strides made in EV testing resonate far beyond the automotive industry, shaping a cleaner, greener future for generations to come.

The E-Axle is becoming a critical factor in developing a compact full-electric #powertrain. The testing & optimization of modern E-Axle assemblies requires a highly sophisticated approach.

Our E-Axle Dyno Drive is developed explicitly for E-Axle testing, offering an energy-efficient #test solution and simple configuration for a wide range of e-Axle and E-Drive units.

Highlights

Why are Electric Ships a Popular Alternative to Conventional Ships?

Latest Trends in Electric Ships

Electric Powertrain Design for Ships

Importance of Fiber Optic Temperature Sensors in EV Thermal Management

Rugged Monitoring Sensors and Monitors for EV Testing

Why are Electric Ships a Popular Alternative to Conventional Ships?

Maritime transportation contributes to more than 2% of worldwide greenhouse gas emissions and transportation across water bodies is expected to increase by 3.8% by 2022. A worrying discovery is that the amount of nitrogen oxide and sulphur oxide pollutants produced by the 15 largest cargo ships is greater than the pollutants released by all the cars in the world. Scientists predict that if we do not convert to cleaner means of energy then air pollution levels will increase 250% of current level by 2050 and maritime traffic responsible for almost 20% of global carbon dioxide emissions.

Therefore, electrification of ships is very important for countries to meet their environmental targets. Other reasons behind the high growth of electric ship industry are, increase in seaborne trade, IMO Sulphur 2020 regulations and growing maritime tourism. The major challenges electric ship industry is facing are:

The conventional Li-Ion battery pose a great safety risk due to thermal runway issues

Current EV batteries (Li-Ion) does not have enough power to move cargos around the globe.

Latest Trends in Electric Ships

Several new types of batteries have been proposed to be used in electric ships and many of them have already been implemented with the most famous option being the lead-acid batteries. Additionally, battery technologies such as lithium-ion, fuel cells are being tested to be used in electric ships and recently a new electric ship had a mix of lithium-ion batteries and ultracapacitors which allowed for an energy capacity of 2.4mWh.

EV Traction motors of electric ships allow better speed, control, flexibility in architecture and reduced noise and vibration levels. We still need better performing traction motors with high energy efficiency for large vessels.

The need for higher voltage is just as important as a high-density battery with a large capacity. The power train operating voltage increases with larger vessels that are needed for the transportation of large containers. A higher voltage input allows us to have a smaller generator, motor, and cables which would save money and weight.

The EV battery and the EV motor help determine the range of any vehicle which is crucial as it dictates how far someone can travel before needing to refuel. Currently, the longest range of an electric ship is 12000 miles at 12 knots which is possible because of having big solar panels that create 150 kW which fuels the motor.

However, the ship will need to be charged at some time and this sector of the industry has been seeing some very impressive advancements. For example, a German company has presented an inductive charging system for electric ferries. This wireless charging technology is already been implemented in Norway and it is said to reach charging capacities up to 100kW while the ferries only wait for a few minutes at each stop.

The innovations are happening almost every week in this industry with an objective of making electric ships a commercially viable option.

Electric Powertrain Design for Ships

The companies that design and manufacture these electric ships have an uphill battle of creating an EV design that house internals which can be comparable to its gasoline fuelled counterparts. As the new technologies are being developed, these engineers need a capable testing tool that provides precise and reliable results at high voltages.

The new developments and new testing environment need safer, accurate and fast responsive sensors. These new technology sensors must reduce the test setup time and provide flexibility to test EV powertrain for all real-life conditions.

The performance and aging of EV powertrain depend on the temperature distribution and developing hot spots within EV motors, EV inverters and batteries. Therefore, identifying the hot spot location and continuously monitoring them during the EV test cycles helps in improving EV powertrain design.

The accurate thermal profiling of Motor stator winding and cooling duct enables in selecting right kind of insulation, design for better cooling and optimizing motor control algorithm. Similarly, accurate thermal profiling of EV battery modules and battery pack helps in avoiding thermal runaway situation at later stage.

Fiber optic temperature sensing technology is gaining a lot of interest among EV design engineers for prototype testing of EV Powertrain.

Importance of Fiber Optic Temperature Sensors in EV Thermal Management

The traditional sensors such as thermocouples are quite slow, and they deliver inaccurate results, especially when installed at high voltages. These sensors also pose a serious risk of short circuit or electrocution if not being isolated properly.

Fiber optic temperature sensing technology overcomes the challenges of conventional temperature sensors (thermocouples). The following feature of FO temperature sensors make them ideal for EV prototype testing:

Highly Di-electric, Safer to be used in High Voltage environment

No need for complex isolation and lengthy calibration/compensation

Ultra-small size (up to 0.4mm) to fit into Power Module and Battery cells

High accuracy, ±0.²⁰C with 100% repeatability

High Response time <40ms

Robust and easy to route cabling

The fiber optic temperature sensors are being used by EV design, instrumentation, and test engineering in the following applications:

Traction Motor Testing: Stator winding hot spot, Rotor temperature, HV Terminals temperature measurement.

Power Electronics Testing: Junction Temperature (IGBT, Diode), Capacitor Core Temperature, and HV Terminals temperature testing

EV Battery: Cell Core/Anode thermal profiling, Intercell temperature, Battery Pack Hot Spot, HV Terminals temperature, Cooling thermal profiling, Battery Abuse Testing etc.

Rugged Monitoring Sensors and Monitors for EV Testing

Rugged Monitoring (RM) has developed several products such as the LSENST and LSENSB sensors which utilize fiber optic technology of temperature measurement. The sensors are being used by major EV manufacturers globally, in measuring temperature of high voltage components such as EV battery, EV motor, charging boards, HV connectors, EV inverters and power electronics.

Vehicle Prototype Testing

High performance, longer range, fast charging, and cost-effective design are the major objectives for Electric vehicle (EV) design and test engineer. Effective thermal management of the vehicle is the key to meet these objectives.

Our faster and accurate fiber optic temperature sensors are the ideal choice for testing high voltage EVs and helping design/test engineers to meet their objectives:

Bring safety compliance to the test setup; Avoid thermal run-away issues

Reduce test set-up time while covering for all test-conditions

Increase pass rate with accurate performance assessment

EV Battery Design Validation and Abuse Testing

Accurate thermal profiling and early detection of thermal run-away issues are very important in designing a high-performance EV battery and avoiding product recalls. Better the temperature measurement more accurate and effective is the Battery Management System.

Rugged Monitoring’s Fiber optic temperature sensors are being used by battery design/test engineers at each stage for battery testing:

Battery cell core and anode thermal profiling for fast charging

Intercell temperature monitoring in Battery Modules

Battery pack abuse testing and HV connectors temperature testing

EV Motor Design Testing and Vendor Evaluation

Stator winding hot spot monitoring during the testing of EV motors is crucial as it helps in:

Better insulation selection and cooling management

Improving performance with better control algorithms

Accurate performance rating and Age estimation models

Rugged Monitoring’s Fiber optic temperature sensors are being used by major EV and motor manufacturers in their design, testing, and vendor evaluation stage. These fast responsive and accurate sensors can directly be installed at stator windings and high voltage connectors without any isolation.

EV Inverter / Power Electronics Testing

Measure accurately and manage effectively. Faster and accurate temperature measurement in EV inverter is a big challenge for inverter engineers due to their compact size, and high-power density.

Rugged monitoring provides high dielectric, fast responsive, smaller size, and accurate temperature sensors for EV inverter testing. Our sensors are being used in inverter testing for:

Direct and Accurate measurement of Junction Temperature (Tj)

Capacitor Core temperature measurement without thermal run-away issues

Cooling and HV connector thermal profiling

Charging Board & Charging Plug Testing

High voltage and Fast charging are the future of E-mobility. The key challenges that need to be addressed are how to make:

Safe charging plugs both from high voltage and temperature

High-performance on-board charger for fast charging

Rugged Monitoring’s fiber optic temperature sensors are faster, accurate, and smaller to fit into charging plugs and compact on-board chargers. The high dielectric strength of our sensors makes them most suitable for Tj (Junction Temperature) measurement in on-board Chargers and thermal profiling of charging pins in fast charging plugs.