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E-Axle Dyno Drive

E-Axle Dynamometer Drives to test the EV propulsion system, simulating resistance at the axle of the vehicle. Common DC Bus offers flexibility, cost savings, and configuration not normally possible with traditional drives.

Develop and test your EV propulsion systems with simulated resistance using Unico’s E-Axle Dyno Drive.

This leading edge E-Axle dynamometer is a modular design that allows for multiple types of drive elements to be connected to the common DC bus. Combine mutliple AC dynamometers and E-Motors with a battery emulator and univeral inverter. Power ratings from 50kW to 1000kW, with higher power options available. Support induction and permanent magnet motor dynamometers. Highly efficient and fully regenerative, the system is capable of steady state, transient, and high dynamic simulations. Supports most industry standard communication protocols, making it versitile to work with any automation systems platform. Multiple programmable and preset safety features. Enclosures can be ordered with air cooled or water cooled designs.

Features

Testing Applications

E-Drive Dynamometer Drives to perform repeatable performance testing on the E-Drive under test. High efficiency design, high speed, water and air cooled options, and ratings up to 5MW.

Precision Control and Flexibility

Unico's E-Axle Dynamometer Drives uses a modular design inverter for full regeneration to the three-phase power grid. A proprietary digital current regulator and a state-of-the-art controller allows you to operate any AC dynamometer motor (Asynchronous Induction, Synchronous Permanent Magnet, and IPM - Internal Permanent Magnet) without the current-loop setup required by conventional drives. And IGBTs with a switching frequency up to 30kHz, gives you the performance to run high speed dynamometer motors to match high speed requirements of the E-Motor under test.

Incredible speed and torque response with acceleration rates up to 300,000 rpm per second so you can confidently test with realistic load resistance for aggressive launch control modes, motoring, hill climb, and a variety of throttle applications. Ultra-quiet operation mode using built-in dual current regulators is ideal for NVH testing in both anechoic and hemianechoic test cells.

Preprogrammed

The drive features full automatic tuning capabilities that can be operated from either a remote terminal or the drive’s built-in keypad. After entering the motor nameplate data, the auto-tuning algorithm automatically identifies the additional parameters for operating the attached motor and configures itself for operation.

Unico’s dynamometer drive provides internal inertia simulation. The inertia simulator can simulate both fixed and dynamic inertias using either internal inertia models or an external real-time command from another controller.

Protection

Supports most industry standard communication protocol, making it versatile to work with any available automation system platform. A high-speed communications interface is optionally available to accept commands from existing customer controllers that are used to generate test profiles. Wired and fiber-optic options are available. Supported protocols include:

  • CANopen
  • CC-Link
  • ControlNet
  • DeviceNet
  • Ethernet
  • EtherCAT (async)
  • Interbus
  • LonWorks
  • Modbus Plus
  • Profibus DPV1
  • Profibus Master
  • EtherCat (sync)

Safety and Protection

Built-in safety and control interlocks are hardwired, opto-isolated, and software configurable to protect your investment and team. And with cabinet enclosure cooling options of air-cooled, water-cooled, and air-conditioned, this system will keep up with your testing and development program.

Specifications

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Unico Features

General Specifications

Power 30kW to 1100kW
Motor Voltage 230 VRMS, 460 VRMS, 520 VRMS, 690 VRMS
Full Four Quandrant Standard
Max Dyno Speed 30,000 RPM
Fundamental Frequency 1500Hz
Encoder Type Resolver, Quadrature, SinCos
Internal Data Logging 250kHz or higher
AC Input 480Vac, 3Ph, 60/60Hz (other voltages available on request)
Ambient Up to 40°C, max 1000m above sea level, 95% RH non-condensing
Enclosure NEMA 1 (other options available upon request)
Cooling Air cooled (water cooled or airconditioned cabinets upon request)
Cabinet Paint RAL 7035 Rough Semi-glass Poly Powder finish
Certification Compliance UL (other certifications available)
Control Local and remote
Built in remote interface Analog as well as RS-422, RS-485, two ports (other interface and protocol, see options below)
Safety and control interlocks Hardwired, opto-isolated, software configurable
Unico Features

Options

Isolation transformer Various sizes as required
Insulation monitoring Available
Remote voltage sensing Available
Additional analog and digital input, output Technical discussion required
Cabinet paint finish Customer specific
Protection class NEMA 12
External communication interface CANopen, CC-Link, ControlNet, DeviceNet, Ethernet, EtherCAT (async), Interbus, LonWorks, Modbus Plus, Profibus DPV1, Profibus Master, EtherCat (sync)

Block Diagrams

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Brochures

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Resources

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Application used for Automotive

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Battery

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Inverter

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Inverter

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Battery

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Inverter

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Battery

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Inverter

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Battery

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Inverter

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Battery

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Fuel Cell

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Frequently
Asked Questions

The e-axle or e-axle drive combines an electric vehicle’s gear, motor, and power-control electronics. It acts like a brain for electric vehicles and keeps the functioning smooth. 

E-axle combines a motor, inverter, and reducer and installs the set in a vehicle. With an electric supply, the drive does everything from generating rotating torque to driving the electric vehicle.

This drive can take the load off diesel or gasoline engines and provide auxiliary electrical power. This system plays a vital role in every type of EV and HEV testing so vehicles can function smoothly and flexibly. 

The function of an e-axle drive is to combine three powertrain components into a single entity, namely motor, power electronics, and transmission. The aim is to make electric mobility more reliable and efficient.