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E-motor Emulator

E-Motor emulators for testing electric vehicle traction inverters. Validate and test inverter designs to prevent prototype e-motor failure.

Develop and test your EV / HEV traction inverters using Unico’s E-Motor Emulator.

This extraordinary E-Motor emulator is specifically designed for testing vehicle traction inverters without risking damage to a production E-Motor. The drive system acting as the emulator has a high switching frequency to replicate the exact power, voltage, and current demands of the E-motor. So you can test hundreds of traction inverter designs, and never worry about having an expensive E-Motor failure due to incorrect inverter performance. 

Features

Testing Applications

Testing of traction / drive inverters before a real E-Motor is available. Validate the traction inverter to prevent expensive protoype E-motor failure due to incorrect inverter performance.

Precision Control and Flexibility

Unico's E-Motor Emulator has a fundamental frequency of 1500Hz, emulates motors from 2 to 64 poles, and provides model calculation up to 30kHz. The silicon IGBTs provide a sampling frequency from 1 kHz (1.0 ms) to 10 kHz (0.1 ms), so you can replicate the quick response of a real E-motor to changing commands or load levels. Option the silicon carbide (SiC) MOSFET to emulate high speed E-Motors with even higher switching frequencies.

No moving parts means you’ll achieve a higher level of safety in boundary condition testing. And with more complete testing than HIL (hardware in the loop) or passive load emulation, it’s the ideal tool for EV propulsion engineers.

Preprogrammed

Fault injection verification makes it simple to track behavior and determine where error occurred: harmonics, 3 phase open circuit, phase to phase, phase to ground short circuit, motor stalling, motor over torque, winding asymmetry, demagnetization, sensor phase shift – it’s designed to help you go fast, and build the ideal traction inverter in less time.

High Speed Link

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 230kW to 800kW/td>
Motor Voltage 230 VRMS, 460 VRMS, 520 VRMS
Number of Poles 2 to 64
Power Factor Standard
Back EMF Standard
Full Four Quandrant Standard
Inertia Torque Standard
Fundamental Frequency 1500Hz
Encoder Type Resolver, Quadrature, SinCos
Resolver Lobes: 2 to 64 Offset: -2π to 2π radians Excitation: 2kHz to 20kHz
Programmable Parameters Direct inductance Ld Quadrative inductance Lq Magnetic flux Winding resistance /td>
Fault Simulation Harmonics 3 Phase open circuit Phase to phase short circuit Phase to ground short circuit Motor stalling Motor over torque Winding asymetry Demagnetization Sensor phase shift
Internal Data Logging 250kHz or higher
Model Calculation Up to 30kHz
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)
Remote 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
Battery Emulator Specification Many different voltages, current, power ratings available (View Battery Emulator Brochure)
Unico Features

Options

Isolation transformer Various sizes as required
Insulation monitoring Available
Remote voltage sensing Available
Additional analog and digital input, output 48Technical discussion required0V
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

A battery cycler measures the cell response over time and analyzes battery function by charge/discharge cycles. The parameters you can calculate using a battery cycler include capacity, self-discharge, and efficiency, among others. You can also use a battery cycler with capacitors and super-capacitors. 

It is effortless to use a battery cycler system, and you can use it simply by following these steps:

  1. Turn on the multimeter and then choose the mode named ‘DC voltage’.
  2. Now, connect the multimeter test leading to the battery terminals. 
  3. Read the voltage shown on the gauge or multimeter display.
  4. Load the battery with a satisfying result or repeat the process.

A battery cycler is important to test the available batteries and make the improvements. It is one of the integral components of battery laboratory testing equipment that many R&D experts use for battery cycling and DC testing.

The Unico battery cyclers combine the family of single and dual output DC power supplies with software specifically tailored for testing HEV battery packs, ultra and supercapacitor packs, fuel cells, power electronic converters, and other devices.