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Demo | Signal-Level HIL with the New Inverter HIL Test System | OPAL-RT Learning Journey

Author : Brian Kindinger and Brandon Brice

Traction inverter design engineers and testers routinely test hybrid and electric vehicle inverters for software and signal-level electrical features using a closed-loop simulator. Physical testing with a dynamometer is costly, limited in coverage, and presents potential safety issues and risks for expensive hardware test equipment. Combined with the challenge of rapidly evolving Devices under Test (DUTs), it is becoming increasingly difficult to meet ever more stringent time-to-market requirements. By simulating EV powertrains to perform Hardware-in-the-Loop (HIL) tests of traction inverter electronic control units (ECUs), the Inverter Test System (ITS) allows EV test engineers to create more life-like scenarios not easily and accurately reproduced on the road. The motor and power electronics are modeled using OPAL-RT's Power Electronics Add-on. In this demo we connect a development ECU to the ITS, execute a typical 2-level inverter model with attached machine, and perform speed profiles in normal operating conditions. Then we will change gears and walk users through mapping testing requirements to the ITS configuration to identify how the ECU will react under faulting conditions. Finally, we will record high-speed data from the system as it runs a test sequence so that it can be visualized and analyzed offline by ECU developers.