D7.2 Test setup prototype

Executive Summary

The main purpose of the present deliverable is to describe the test setup for the verification of the monitoring system that has been defined and implemented during WP7.

The PHMS is based on the monitoring algorithms developed during WP4 [8] to monitor the condition of those FEV components and degradation mechanisms which were previously identified as the most critical: magnetic field source, bearings, motor stator windings, DC-Link capacitor and IGBTs. These algorithms rely on the measurement of some physical characteristics associated with the condition of such components.

During the WP6 [9], the architecture of the PHMS system was defined. Finally, a functionally integrated but physically distributed architecture was selected, in which the algorithms are implemented in a Central PHMS, and several Satellite PHMS units are used to get the monitoring variables, pre-process them if necessary, and send the information to the Central PHMS. A CAN communication bus has been selected for the communication between the different PHMS units, as well as between Central PHMS and the rest of the vehicle.

In WP2 [10], the test cases to be used for the validation process were defined. These test cases were defined at the beginning of the project and there were reviewed after WP4 finished, as some new information arose from this WP. These test cases have also been reviewed and modified by IDIADA and CEIT at the beginning of the WP7.

Having taken into account all these inputs coming from previous phases of the project, a test setup has been defined and implemented, with the purpose of validating the performance of the system developed.

For the validation of the system, two different test benches have been proposed. The first test scenario will be the Engine Test Laboratory already existing at IDIADA, where a real powertrain consisting of a real motor and its control will be tested with the PHMS system. As some tests will not be possible to be performed in the test bench for safety reasons, it will be necessary to perform some of these tests using simulated signals as an input, to simulate the failure behaviour of the powertrain. According to all these constraints, all the hardware to be used for the test setup has been defined. National instrumentsí compact embedded real time controller RIO 9002 [5] with CAN module NI 9853 [4] has been used to build the Hardware-in-the Loop simulator for the HEMIS project. This application software has a GUI which can be used to send/simulate various test inputs and monitor the reaction of the central PHMS. In a later phase of the project, test scripts will be developed to automate the entire testing process.


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Project acronym:

Project name:
 Electrical powertrain Health Monitoring for Increased Safety of FEVs

Project reference:

Start date: 01/06/2012
End date: 28/02/2015

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