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Electric Vehicle Test Cell Control and Data Acquisition System

A complete off-the-shelf solution for deterministic real-time testing of components or full vehicle eDyno. 

Benefits

 

  • Open platform provides greater modularity, flexibility, model integration and custom sensors.
  • Quick and easy to deploy, configure and replicate.
  • Reduce cost and complexity with a future-proof platform.
  • Achieve complete test coverage with a flexible platform.
  • Enable accurate and innovative powertrain test systems.
  • Achieve faster development times with automation and collaboration.
  • Adaptable to rapidly accommodate changing project requirements.
  • Independent review of requirements and outsourced testbed completion.
  • Integration with existing systems.
  • Detect defects earlier through scalable testing.

System Overview

The world global Electric Vehicle (EV) market is increasing rapidly. The number of EV models available is set to jump from 155 at the end of 2017 to 289 by the end of 2022. By 2040 55% of all new car sales and 33% of the global fleet will be electric.

This rapid rate of development combined with new and emerging technology implementations and complexity is driving increased demand for new test systems and architectures. Test cells require a much more modular approach; combining standard frameworks and commercial–off-the-shelf (COTS) hardware this Test Cell Control and Data Acquisition System provides a low-cost route to a re-configurable, flexible, modular, expandable solution.

The EV Test Cell Control and Data Acquisition System is a complete, off-the-shelf solution for either real-time component testing or full vehicle eDyno testing. The system has been designed with a deterministic real-time test engine at its heart, to ensure that the system can run high-speed models and close the loop with real sensor data at rates upwards of 1 kHz.

With the National Instruments hardware and software platform at its core, the system has also been designed with maximum flexibility and extensibility in mind.

The modular system comprises

  • Test Cell Control and Data Acquisition System
  • Test Cell Management Unit
  • Optional: Power Analyzer Rack and Remote Patch Panel.

Key Features

High-speed deterministic modelling and control. (HiL)

The software provides the ability to run many different types of models, ranging from MATLAB/Simulink, AVL Boost and Cruise, TechnaliaDynaCar, IPG CarMaker to simple models built in LabVIEW or pure C code.

Intuitive test sequencing and scripting via Python scripting engine.

No need for high-level programming experience. Predefined test-steps for configuration and test profile creation. Integrated Python scripting tool allows new steps to be created for applying calculations to channels, importing new file formats and other requirements.

Multi-link capability

Multi-link capability- deterministic high-speed data sharing between multi-axis or systems for maximum scalability to facilitate multiple test applications.

USER LEVEL BASED ACCESS

Multiple Configurable User Access Levels ensure ease of use,  extensibility, system security, and allow new scripts and testing sequences to be generated and low-level functionality increased.

Channel mapping with calibration and alarming.

Assign specific physical channels to in ports and out ports in models. Name channels appropriately for your specific test. Apply scaling and calibration for your sensors.

Open extensible architecture.

Based on NI PXI modular hardware platform offering a cost-effective, adaptable solution for changing hardware requirements. Flexible to accommodate new technologies and extendable chassis for increased demands. Add new sensors, or bespoke protocols via a simple low-cost, ‘plug-in’ upgrade. 

Data-logging

All Data is synchronised, time-stamped and logged to TDMS file format. Plug-ins are available for both MATLAB and Microsoft Excel™.

Dynamic User Interface

Configure and save user interface in the test. Create profiles specific to your requirements. No need to restart the test.

Signal isolation.

Optional galvanic isolation provided via the Test Cell Management Unit.

Main Control System Specification

The main control system consists of a quad-core 2.6 GHz i7 processor running a real-time operating system, for maximum determinism. This allows high-speed models to be run up to 3 kHz. Data acquisition channels will run at the same speed as the model (typically 1 kHz) with the exception of the high power measurements, which include a snapshot mode for acquiring signals at 500 kHz for short bursts.

The unit is configurable on request, however, as standard, offers:

Cell Configuration

EV Test Cell Safety Configuration

Cell Services

Dynamic User Interface

Python Scripting Tool

DAQ unit and Power Analyser Rack

As part of the NI ecosystem of solutions, the system is able to integrate with the wide range of commercial-off-the-shelf ADAS solutions, and expertise developed and supported by the National Instruments community of Alliance Partners.

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