E-motor EMC testing

The e-motor EMC testing solutions provided by DynoEquip are specifically designed to meet the increasingly stringent demands of compliance and performance testing in the automotive industry. These comprehensive solutions are both economical and efficient, ensuring repeatable testing outcomes across a variety of configurations.

The offerings include full vehicle setups that feature multi-axle chassis load machines, four-wheel drive capabilities, fully automated remote antenna positioning, and specialized charging mode test configurations. This versatility allows for thorough evaluations of both complete vehicles and Electric or Electronic Sub-Assemblies (ESA), making these solutions suitable for a wide range of applications.

One of the key options for load machines is the conventional through-shaft EMC chamber installation, which adheres to the CISPR 25 standard. This type of installation is particularly effective for testing e-motors ranging from modest 20 kW motorcycle to larger units up to 700 kW, which are commonly found in commercial vehicles. It is capable of addressing the full spectrum of e-motor dynamic requirements, ensuring that all performance characteristics are accurately assessed.

For scenarios where the load machine is not intended to be a permanent fixture within the chamber, DynoEquip offers mobile testing equipment as a versatile alternative. This mobile setup is designed for use in multi-use or existing EMC chambers, providing the same comprehensive feature set and functionality as stationary systems while accommodating a more limited power capacity range.

The e-motor EMC testing solutions also include component test sets that cover the entire range of e-motor torque and speed for both commercial and passenger vehicles. These sets are equipped with options for cooling, battery simulation, inverter emulation, and four-quadrant operation, making them highly adaptable to various testing scenarios. This ensures that manufacturers can thoroughly evaluate the performance and compliance of their e-motors under different operational conditions.

The efficiency and repeatability of e-motor EMC testing are complemented by automated setups that streamline the compliance and performance testing processes. Standard immunity test methods are provided for both whole vehicle and component testing, along with expert guidance and support to help manufacturers navigate regulatory compliance requirements effectively.

In addition to testing individual components, a vehicle’s entire EMC anechoic chamber can also be employed for automotive component evaluations. According to the most recent CISPR 25 and ISO 11452-2 standards, the Unit Under Test (UUT) support must utilize a ground plane bench, which can be temporarily established with the necessary support equipment within a 10-meter-long chamber.

Mobile testing equipment can be brought into the EMC chamber to facilitate the testing of e-motors and inverters. This portable setup features cable and communication management systems designed to maintain the RF integrity of the chamber configuration. It also offers the same options for coolant conditioning and battery simulation as the stationary systems, ensuring comprehensive testing capabilities regardless of the testing environment.

Stationary e-motor EMC testing for CISPR 25 and ISO 11452-2

The e-motor EMC testing setup includes a load machine, which is essential for evaluating the performance of the e-motor and controller under test. This component distinguishes stationary e-motor EMC testing from traditional no-load arrangements, where motors operate without any resistance. The load machine enables the e-motor and controller to function under realistic conditions that closely mimic actual driving scenarios.

Drive components typically operate at much higher voltages than the standard 12 V DC used in conventional electronics, necessitating additional safety measures to minimize electric shock risks. These protocols ensure a safe testing environment given the potential hazards of high-voltage systems.

Unlike the no-load method, the load machine allows the e-motor and inverter to operate at full load in both drive and regeneration modes. This capability enables the inverter to power the e-motor while simultaneously charging the battery, accurately simulating real-world operating conditions.

Testing under these conditions provides engineers with critical insights into the e-motor’s efficiency, reliability, and overall performance during peak power demands and regenerative braking. This comprehensive approach to e-motor EMC testing allows for thorough evaluation and optimization of electric drive systems, ultimately leading to improved product development and compliance with industry standards.

Direct drive type test (up to 15,000 rpm)

Test with additional gearbox (from 15,000 rpm)

Mobile e-motor EMC testing

Completing the comprehensive range of load machine options for electric vehicle (EV) component EMC testing is the innovative mobile e-motor EMC testing solution. This mobile setup features an EMC load machine equipped with advanced drive electronics and controls, all housed within a shielded container that forms part of a free-standing mobile unit.

This configuration allows for complete four-quadrant (4Q) operation, enabling the testing of both e-motor drive and regenerative functions. Importantly, the entire test setup adheres to current emission and immunity standards, ensuring that there is no compromise in the quality of the measuring environment.

One of the primary advantages of the mobile e-motor EMC testing solution is its versatility in conducting e-component testing within existing EMC chambers that are typically designed for consumer electronics or complete vehicles. This capability allows for minimal modifications to the testing environment, making it a cost-effective solution for manufacturers.

Many of these chambers are already equipped with essential features such as turntables and raised flooring, which facilitate the routing of signal fiber optics and power cables beneath the floor void. This design consideration streamlines the setup process and enhances operational efficiency.

To further optimize efficiency, the Unit Under Test (UUT) can be set up on the mobile load machine outside of the EMC chamber. Once the assembly is prepared for testing, a standard pallet truck can easily transport the entire setup into the chamber, where it can be quickly connected to the power supply. This efficient transfer process minimizes downtime and maximizes productivity during testing sessions.

Additionally, the modular nature of the transportable platform allows for customization to meet specific testing requirements. For instance, if higher speed or torque tests are needed, a larger and more capable load e-motor and drive can be added to the system. This flexibility ensures that the mobile e-motor EMC testing solution can adapt to the evolving needs of manufacturers and researchers, providing a robust and effective platform for comprehensive EMC evaluations of e-motor components.

Advantages and disadvantages of stationary and mobile e-motor EMC testing

Advantages of stationary type e-motor EMC testing solution

• For the CISPR 25 and ISO 11452-2 tests, a larger chamber than the minimum is needed.
• Load machines and support cabinets permanently placed to meet maximum drive capacity.
• For optimal speed and torque, use stationary, sturdy supports.
• It is possible to permanently install one or more load machines for various e-drive combinations.
• Stationary or movable height and several e-motor installation options
• More adaptability in terms of capacity and test capabilities
• Permanently mounted outside the chamber are all necessary conditioning units and inverter drivers.
• Inside the chamber, higher field levels are possible.

Disadvantages of stationary type e-motor EMC testing solution

• Chamber size can be either standard or customized to meet maximum UUT
• Restricted to maximum capacity
• Upgraded setup and reinforcements are required.
• Designing a custom chamber is necessary for e-axle combinations.
• A perhaps bigger and more intricate platform is needed.
• Maybe more expensive than a mobile upgrading option in a chamber that already exists
• More room is required outside the chamber to accommodate the DC simulator, coolant conditioner and drive cabinet.

Advantages of mobile type e-motor EMC testing solution

• A spacious room is offered for testing the entire vehicle or individual parts.
• Simple switchover to configure a module test
• Choosing a unit depending on the capacity needed
• Cables can be permanently run beneath the floor.
• Moving with ease
• Perhaps less expensive to update mobile than to install stationary
• Inbuilt cooling and inverter drivers for load machines
• Suitable for R&D 360° measurements when utilized with an optional turntable
• Since the design is tiny (<1 m wide), it may be utilized as an update in current EMC chambers.

Disadvantages of mobile type e-motor EMC testing solution

• The only testing that can be done simultaneously is module testing or whole vehicle testing.
• The amount of setup time required for switching
• Restricted top speed and torque levels
• It is necessary to have additional access to cable-connecting locations.
• For moving, a pallet truck or forklift is required.
• Limited ability to modify test capabilities
• Only installed components have the capacity.

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