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Start for freeExploring UTAC's Cutting-Edge E-Motor Testing Capabilities
The automotive industry is rapidly shifting towards electrification, and with this transition comes the need for advanced testing facilities to ensure electric vehicle (EV) components meet the highest standards of performance, efficiency, and durability. UTAC, a global leader in vehicle testing and certification, has risen to this challenge with its state-of-the-art e-motor testing facility in Northville, Michigan.
In a recent visit to the UTAC facility, we had the opportunity to speak with Don Wright from Unico and Dustin Harrison from UTAC about the innovative testing equipment and methodologies employed to push the boundaries of EV powertrain development.
The Evolution of Testing Facilities
Dustin Harrison explained how UTAC has adapted to the changing automotive landscape:
"What we have here is basically an ultra-high-speed motor that is being powered by the Unico drives. This enables our team to perform motor development testing on the inverter and work on calibration for how the motor needs to respond in the vehicle."
The facility, which was once used for internal combustion engine testing, has been transformed to meet the unique demands of electric powertrains. This conversion highlights the industry's shift towards electrification and the need for specialized testing equipment.
Advanced Testing Capabilities
The UTAC facility boasts an impressive array of testing capabilities, including:
- High-speed motor testing up to 25,000 RPM
- Inverter calibration and characterization
- Thermal cycling and extreme temperature testing
- Durability and long-term performance evaluation
- Efficiency optimization
These capabilities allow automotive manufacturers to fine-tune their electric powertrains for maximum performance and efficiency.
The Importance of Motor-Inverter Integration
One of the key challenges in EV powertrain development is optimizing the integration between the electric motor and its inverter. Dustin Harrison emphasized this point:
"We 100% saw that at the beginning, where one manufacturer was buying the inverter from XYZ company and getting the motor from ABC company, thinking they could just mix them together. But that's not how it works in the real world. We've got to do a bunch of calibration and engineering work behind the scenes to make sure that thing's actually going to perform the way everyone expected it to."
This integration process can take anywhere from six months to a year to fully optimize, highlighting the complexity involved in EV powertrain development.
Cutting-Edge Equipment from Unico
At the heart of UTAC's testing capabilities is the advanced equipment provided by Unico. Don Wright walked us through some of the key components:
Silicon Carbide Drive System
Unico's latest technology features a silicon carbide drive system, which offers several advantages:
- Higher efficiency
- Ability to handle higher voltages (up to 1200V)
- Compact design
This system is particularly relevant as the industry moves towards 800V and 900V battery systems in high-performance EVs.
Modular "Lego-like" System
Unico's equipment is designed with flexibility in mind. Don Wright explained:
"We give them a bunch of different active front ends of different powers. They have DC sections that act as battery emulators or simulators, and then we have dyno sections and universal inverters. Depending on the project, UTAC can put these pieces together to create a test system that matches exactly what their customer needs."
This modular approach allows UTAC to quickly adapt their testing setups to meet the diverse needs of their clients.
Energy Efficient Design
The Unico system is designed with energy efficiency in mind. It features a common DC bus that allows for energy recirculation, minimizing the overall power draw from the grid. This design not only reduces operating costs but also aligns with the sustainability goals of the EV industry.
Advanced Battery Emulation
One of the most critical components in EV powertrain testing is the battery emulator. This sophisticated piece of equipment can simulate the behavior of a real battery pack under various conditions. Don Wright explained the two primary modes of operation:
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Stiff Voltage Supply: This mode maintains a very stable output voltage, allowing engineers to accurately assess the efficiency and power capability of electrical components.
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Battery Model Emulation: This mode replicates the voltage drop characteristics of a real battery based on factors such as state of charge, state of health, and temperature.
The ability to switch between these modes allows for both detailed component testing and pre-integration work, streamlining the development process.
Flexibility and Future-Proofing
A key feature of UTAC's testing facility is its flexibility. Dustin Harrison emphasized the importance of this approach:
"These are multi-million dollar investments. They want it to be able to run anything that they have in their program. Flexibility is really, really important because we only get so much capital money before somebody comes back to us and says, 'Hey, you're all out of cash.'"
This flexibility extends to the physical setup of the test cells. The facility features:
- Modular bed plates with various attachment points
- The ability to swap different motors and inverters quickly
- Test cells that can be reconfigured for different types of testing
This adaptability ensures that the facility can remain relevant and useful as EV technology continues to evolve.
The Challenges of High-Speed Testing
Testing electric motors at speeds up to 25,000 RPM presents unique challenges. Dustin Harrison explained:
"When you start to get above 10,000 RPM, you really start to see a lot of issues with vibration. Everything about the design, the layout, the fixturing - it's all part of addressing these challenges."
To combat these issues, UTAC employs several strategies:
- Heavy-duty steel fixturing
- Full FEA (Finite Element Analysis) on all equipment
- Seismic mass isolation for test cells
- Liquid cooling systems for high-speed dynamometers
These measures ensure that the facility can safely and accurately test the next generation of high-performance electric powertrains.
The Future of EV Testing
As the EV industry continues to evolve, so too will the testing methodologies and equipment. Some exciting developments on the horizon include:
DC Microgrids
Don Wright discussed the potential for implementing DC microgrids within testing facilities:
"We're going to explore putting in a DC microgrid in some of their test facilities. This means we could have multiple test cells powered from one active front end, potentially connected to an energy storage system sitting out on the parking lot in a shipping container."
This approach could significantly increase the energy efficiency of testing facilities and provide greater flexibility in power management.
Integrated Simulation
Dustin Harrison highlighted the growing importance of simulation in the testing process:
"The things that we're now working on with our group is, in theory, we now have the capability with our simulation team to basically run a battery in the UK, tell it how it's responding and pulling current from here, putting it over to that inverter, and I could have a guy running a simulator software where essentially he feels like he's driving a car on the track, mimicked exactly to the Millbrook tracks."
This level of integration between physical testing and simulation could dramatically accelerate the development process for new EV powertrains.
Conclusion
UTAC's advanced e-motor testing facility, equipped with cutting-edge Unico technology, represents the forefront of EV powertrain development. By combining flexible, energy-efficient testing equipment with innovative methodologies, UTAC is helping to push the boundaries of electric vehicle performance, efficiency, and reliability.
As the automotive industry continues its rapid transition towards electrification, facilities like this will play a crucial role in ensuring that the next generation of EVs meets and exceeds consumer expectations. With the ability to simulate real-world conditions, optimize motor-inverter integration, and test components at the extremes of performance, UTAC is well-positioned to support the ongoing revolution in automotive technology.
The future of EV testing looks bright, with developments in DC microgrids and integrated simulation promising to further streamline the development process. As these technologies mature, we can expect to see even more rapid advancements in electric vehicle performance and efficiency, bringing us closer to a sustainable automotive future.
Article created from: https://youtu.be/tG6w-D9VjOc?feature=shared
