JIANGSU GTAKE ELECTRIC CO., LTD.

PowerPard - Battery simulator and four-quadrant drive system

PowerPard - Battery simulator and four-quadrant drive system PowerPard bi-directional DC power source (or battery simulator）adopts buck-boost tactics to control the main circuit, and advanced PWM rectification technology on AC side to realize bi-directional control of DC and AC energy. The system can optimize the power factor and reduce harmonic interference to the grid. On DC side, advanced three-phase staggered current sharing control technology is applied, realizing features for DC bus voltage: high-precision & low-ripple output, adjustable wide range, quick dynamic response, etc.

PowerPard bi-directional DC power source（or called battery simulator）is programmable, and can be secondarily developed and applied with the help of host software or remote test & control software. It can be used for development and test of following applications:

Energy storage system/on-grid inverter system

Energy recycling system

Test system for EV motor/controller

Test system for EV transmission/powertrain system

Test system for dedicated EV motor/controller

Test system for dedicated EV transmission/powertrain system

Test system for electric transmission/driving system of ships/vessels

High precision

High-precision DC output voltage/current^*1
High-precision speed/torque output^*2

Quick response

Fast voltage-adjusting^*1
Prompt speed and torque response^*2

Support high frequency/speed motor with wide compatibility

Support high base frequency PMSMs/ACIMs^*3
Compatible for various speed feedback encoders^*4

Compact, modularized

Modularized, easy to be extended
High energy density, high efficiency

Integrated advantage, sophisticated solution

Application cases for different test requirement
Applicable to high voltage test requirement in the near future

Customizable, optimized configuration

Customizable solutions to meet different test requirements with optimized configuration

Powerful core

High-precision 16-bit AD sampling chip and advanced software sampling timing sequence algorithm are adopted, realizing output voltage precision up to ± (0.1%·FS+5dgt), current precision up to ±(0.1%·FS+5dgt).

Various options for communication

The system is configured with RS485 communication as default, and ProfiNet, EtherCAT, CAN communication as options. Thus, the system can interchange data with the test system, making data statistics and analysis more convenient for users, while improving the automatic efficiency for production.

Excellent thermal performance

The system is designed with independent air duct, and the duct of power modules is isolated from other magnetic components. Copper tube cooling technology is combined, realizing excellent heat dissipation with compact size.

THD < 2%

Advanced PWM rectification technology is adopted on the active front end, which can not only emit/absorb low harmonic distortion current (THD≤3%) from grid, reducing the voltage harmonic, but also control the unity power factor (PF>0.99), and optimize the power factor. Besides, it is compatible to the voltage imbalance of grid, and can withstand sudden change of voltage.

Response time < 5ms

Three-phase staggered buck topology main circuit for DC/DC is adopted, realizing low-ripple AC voltage/current output. Advanced three-phase current sharing technology realizes the balance of three-phase power consumption. Quick adjustable tactics achieves quick dynamic response, and the voltage response time ≤5ms (load changes from 10% to 90%)

Power factor > 0.99

Real-time measured data of 400kW battery simulator

*Driving state

Power factor > 0.99

Real-time measured data of 400kW battery simulator

*Generating state

λ > 0.99

Real-time measured data of 400kW battery simulator

*AC side

Test Equipment for Electric Vehicle Powertrain

Besides the traditional drive control system, electric vehicle powertrain testing usually requires a controllable DC power supply to simulate different output status of the vehicle battery. GTAKE PowerPard system contains battery simulator and four-quadrant drive system, which can not only provide precise power output control for motors, motor controllers, gearboxes and all-in-one products in electric vehicles, motorcycles and a variety of special vehicles , but also manifest the system performance under different output status of the battery according to the test requirements.

Parts with star label are in the scope of PowerPard product supply

Gearbox Test Rig

GTAKE drive system can be used to control the input and output torque and speed of different gearboxes. Whether it is a four-wheel or two-wheel loading gearbox, our control system, by virtue of excellent control algorithms, hardware configuration & bus communication mode, can achieve accurate synchronization of the loading motor, or the differential control according to the test requirements.

To meet the strict requirements of such testing, we usually use low-inertia permanent magnet synchronous motor or asynchronous motor for the input control of gearbox. With torque control mode of input motor and speed control mode of the loaded motor, GTAKE drive system can realistically simulate all the operating status of the gearbox, providing reliable test condition for design verification & manufacture quality assurance. Customers only need to focus on the requirement of the measurement and the analysis of the result.

Parts with star label are in the scope of PowerPard product supply

Engine Test Rig

GTAKE four-quadrant drive system is applicable to the test rig in the phase of development or manufacture of internal combustion engine. In this application, the drive control system can accurately simulate the speed and torque of the vehicles under all kinds of operating and driving status, providing accurate and reliable test data for the performance evaluation, design improvement, calibration or production quality assurance.

GTAKE four-quadrant drive system can not only accurately and quickly simulate the required loading torque, but also feed the regenerated energy from the drive system back to the grid through its AFE unit, reducing power consumption without generating harmonic interference to the grid.

Parts with star label are in the scope of PowerPard product supply

Vehicle Road Simulation Test Rig

With GTAKE PowerPard system, the driving speed and resistance of the vehicle under different road conditions can be simulated, such as bumps, damaged pavement, ups and downs, etc., including all kinds of operations, such as startup, braking, steering and so forth. Properties and performances of the tested vehicle under different road conditions can be realistically recurred.

The internal functions of the vehicle, like the safety features ABS and EPS, can also be simulated by PowerPard system. The system has the characteristics of fast response and precise compensation control, and can perform various measurement requirements - high accuracy, repetition, quick switch, and periodic recurrence, etc. The influence factors such as frictional resistance, electric, thermal dependence, and the inertia moment of the entire power system can be simulated as required. Through bus communication, GTAKE drives are able to achieve quick and accurate synchronous control. Customized PowerPard system solution can meet the requirement of rolling road simulation for the test of pure electric, hybrid and fuel vehicles. Through the common bus structure, the test system can make use of the energy generated in braking status of a motor to another one in driving, or feed the surplus energy back to the grid. The power consumption of the test rig is therefore significantly reduced.

Parts with star label are in the scope of PowerPard product supply

Component Test Rig

In addition to the integral system test requirement, in many industries such as automobile, aerospace, machine manufacturing and military, usually it is necessary to further test some of the components of the system. Through the component test rig, the components of the system can be loaded and tested so as to ensure its performance, safety, reliability and durability, further guaranteeing the system quality, and providing valuable data for the test and analysis of the whole system.

The setup of component test rig is not only significant for its R&D and production quality assurance, but also crucial for the obtainment of relevant qualifications/certifications and customer trust. Compared with system test rig, the cost of component test rig is lower. GTAKE technical team is able to assist customers in setting up new component test rig or upgrading the existing test equipment.

Parts with star label are in the scope of PowerPard product supply

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