E-drive Component Tests Derived from Vehicle Master Test Cases in the SyrNemo Collaborative Research Project

Abstract

SyrNemo is a European collaborative research project that deals with the development of a highly integrated air-cooled next generation E-drive (an E-drive consists of E-motor, inverter and controls) based on a Synchronous Reluctance Machine (SYRM). Its salient features are the use of ferrite magnets and a very high efficiency over a large operation range. Ultimately, any new E drive component has to prove its viability in the vehicle where not only energy efficiency but also functional behaviour is checked. So the goal of the developer is to start the verification of E-drive components as early as possible. For that reason, relevant load cycles for E-drive testing are derived from vehicle driving cases. Vehicle driving functions are verified by so-called Master Test Cases that condense all possible driving manoeuvers into standardized sequences. On the E-drive level, these sequences can be boiled down to Test Primitives since many driving manoeuvers cause similar load patterns for the E-drive components. The most stressful Test Primitives can then be selected from simulations of different driving manoeuvres in vehicle models where the (electrical) load patterns of the components are determined. Because of the ease of simulation, it is relatively straightforward to find out the most demanding scenarios for the E-drive in terms of component ageing, for instance.