E-Mobility

Hybrid Testing

The Dewesoft Combustion Analyzer module allows detailed analysis of the combustion process. The analysis is perfectly synchronized to the power analysis and this gives you the flexibility to test and analyze the entire vehicle with a single DAQ system.

CA module can display and compare measurement data using several different diagrams like the pV-diagram (pressure of angle) or the CA-Scope (pressure over angle). All the specific calculations like the mean effective pressure (IMEP, PMEP), heat release, start/ end of combustion (SOC, EOC), start/end of injection (SOI, EOI), indicated power, maximum pressure (Pmax), derivate pressure (dp/da) are presented either as colour diagrams or as a data tables. For more detailed analysis, statistical calculations per cylinder or over the complete engine can be performed.

Additionally, we provide a dedicated knocking detection and combustion noise algorithm. The basis for all of these calculations is precise angle position data and cylinder pressure measurement. Dewesoft provides the perfect hardware for this task. The galvanically isolated SIRIUS charge inputs (with up to 24-bit resolution and 160 dB dynamic range) which are in perfect sync to the Dewesoft Supercounter inputs. This solution offers perfect analysis of hybrid cars on the road or in the testbed.

Battery Testing

The battery as the central element in the electrical powertrain strongly affects performance and range of electric vehicles. Extensive tests are necessary, starting from the cell characteristics up to the complete powertrain. Detailed analysis requires temperature and voltage measurement at multiple points (e.g. 50x cell voltage and 50x cell temperature). The flexible and scalable Dewesoft solution allows measuring more than 1000 channels from different sensors, all perfectly synchronized.

The DEWESoft® Power Analyzer system can be used for the development of batteries (efficiency analysis, cell characterization, endurance tests, crash tests, short-circuit analysis, overheating/overloading tests, aging tests, etc.) as well as for monitoring applications (data logging, transient recording, charge-discharge analysis, etc.).

Harmonics, Interharmonics and THD

The Dewesoft solution can measure harmonics for voltage, current and additional active and reactive power up to the 3000th order. All calculations are implemented according to IEC 61000-4-7 standards.

You can define the number of sidebands and half-bands for the harmonic order calculation. The higher frequency parts can be grouped in 200 Hz bands up to 150 kHz.

The calculation of THD (overall harmonic content) for voltage and current up to 3000th order and the interharmonics complete the analysis functionalities.

These powerful harmonic calculation functions offer analysis for all types of electrical equipment and devices.

Harmonics calculations

• U, I, P, Q, and impedance

• Individual setup of the number of harmonics including DC component (Example: 20 kHz sampling rate = 200 harmonics @ 50 Hz)

• Harmonics up to 3000th order (@50 Hz)

• Variable sidebands and half sidebands for Harmonics

• Higher Frequencies up to 150 kHz in 200 Hz bands

• Interharmonics, groups or single values

• According to EN 61000-4-7

• Calculation corrected to the actual real frequency

• THD, THD even, THD odd

• Trigger on each parameter

• Background harmonics subtractable

Testbed and on-road Testing

The innovative solution of DEWESoft® allows measuring the energy consumption of electric vehicles on the test bench as well as inside the vehicle under real-driving conditions with the same measurement device.

In-Vehicle Use

For the mobile application, the measurement device can be powered by hot-swappable battery packs so that measurements up to several hours are possible. All sensors (current transducers, GPS, Video) and further equipment like displays can be powered from the measurement device itself. Also, the zero-flux transducer which need a lot of power (up to 20 watts per unit) can be powered via the additional MCTS power slice.

Testbench

The testbench applications require several interfaces (CAN, OPC, DCOM, etc.) to get data and send the data from the testbench control. The Dewesoft X NET option provides remote-control features for the Dewesoft DAQ systems. This allows controlling the whole test procedure from a single PC in the control room.

Exemplary E-Mobility

Standardised driving cycles (NEFZ, WMTC, etc.) are not suitable to measure the energy consumption of electric vehicles. They don’t consider all aspects which influence the energy consumption of vehicles and are always done on roller test benches. The future of electric vehicle testing is analyzing them under real-life conditions. The innovative solution of Dewesoft allows doing all analysis already during the measurement. The sophisticated math functions can calculate different parameters like efficiency, recuperation, etc. and the user-friendly and customizable software interface allows real-time visualization of all these parameters. The chart shows the exemplary energy flow of an electric vehicle.

Some inverters of electric vehicles (e.g. bus) are working at different switching frequencies to increase the efficiency in different driving situations (city/overland drive). With the Dewesoft math library, it is possible to filter out the currently used switching frequency and automatically do the analysis for different switching frequencies (using logical conditions).

Charging Profile, Time and Efficiency

The data logging capability of the Dewesoft Power Analyzer allows recording the complete charging process.

Example photo on the right show analyzing charging profile (red = charging power, orange = energy, violet = power factor):

• Charging part 1: continuous charging with high power. Within 4 hours 80% of the battery is charged.
• Charging part 2: reaching of the charging end voltage and short interruption, 86% charged
• Charging part 3: last charging part with low power. Within 14 hours battery is fully charged.

Additional Automotive Testing Possibilities

Using the Dewesoft data acquisition systems opens you a whole lot of other automotive testing possibilities. Here are some of the applications that you can combine with your power analysis:

• ADAS and Autonomous Driving
• Vehicle dynamics
• Ride and handling tests
• Brake testing
• Pass-by Noise
• Combustion analysis
• Torsional and rotational vibration
• Order tracking
• Road Load Data
• Performance testing
• Component testing
• Modal analysis
• Structural testing
• Crash tests
• Climate and Air-Conditioning testing
• Harsh environment testing