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PowerHIL-Testing

Overcoming boundaries - with PowerHIL between virtual simulation and real performance.

We implement turnkey PowerHIL test systems in which real electrical components such as inverters are connected to a simulated environment in order to test their behaviour under realistic conditions at an early stage of development - including voltage, current and power without the need for a full prototype or field test.

BENEFITS:

  • Early validation of components
  • Reduction of costs and risks through virtual tests
  • Repeatable and controlled test conditions
  • Simulation of error states and extreme conditions (error emulation)
  • Modular and flexibly adaptable to different test requirements
  • Closed powerflow within the device
  • Low grid connection power
  • Only one 50 Hz transformer/mains converter with approx. 20 % of the rated power
  • Less space required
  • Current ripple emulation including saturation effects
  • Encoder emulation
  • Multi-phase machines can be emulated 

COMBINATION OF BATTERYSIMULATION & MACHINE EMULATION

The KS Electric Machine Emulator (KS-EME) enables testing of inverters in an early stage of development or it can be used as a development platform (PowerHIL) for corresponding control concepts. In combination with our battery simulator, the KS-BattSim as a highly dynamic source and sink, a flexible overall system is created with both the highest possible dynamics and at the same time a large power spectrum – all in one system.

Rated Data

BATTERY SIMULATOR:

UBatt = 0 ... 1000 V
IBatt = 1200 A
P = 750 kW
fs = 900 kHz

  

ELECTRIC MACHINE EMULATOR

IEME = 800 A
fs = typically 800 kHz
f0 = 0...5 kHz
Motor types: ASM, PSSM, EESM
 

  • OPTION MCUBE:

    • Universal modular measurment system optimized for highest dynamics
    • Accuracy: less than 100 ppm measurement error
    • Up to 10 measuring channels per cube
    • Latency: < 1 μs
    • Sampling rate: 4 Msps
    • Integrated power supply for sensors (±15V) and evaluation for sensor status signal
    • Modular design with measuring cards and shunt/divider cards
    • Complete galvanic isolation of the channels from earth and from each other
    • Can be used with Tornado & ADAC, KS-AMPS or standalone with PC
    •  Integrated further calculations: e.g: Power measurement

  • OPTION ENCODER EMULATION:

     

    • FPGA processing unit
    • 10 freely configurable analogue outputs
    • Emulation of encoder signals: sincos, resolver, XMR (AMR/GMR)
    • 2 analogue inputs +/- 10V
    • Feedback measurement of encoder signals
    • Communication FC-Link (optical)
    • Use of Simulink models
    • Extensive error emulation