X-in the Loop based high accuracy test facility for industrial development of electric vehicles

• Published in: IEEE transactions on transportation electrification Vol. 9; no. 2; p. 1
• Main Authors: Nemes, Raul, Ruba, Mircea, Raia, Raluca, Martis, Claudia, Oprea, Claudiu
• Format: Journal Article
• Language: English
• Published: Piscataway IEEE 01.06.2023; The Institute of Electrical and Electronics Engineers, Inc. (IEEE)
• Subjects: Accuracy; battery; control; Digital twins; digital-twin; Electric assemblies; electric vehicle; Electric vehicles; hardware in the loop; Hardware-in-the-loop simulation; Industrial development; Laboratory tests; motor; Real time; simulation; Software; Software testing; Test facilities; testing
• ISSN: 2332-7782; 2577-4212; 2332-7782
• DOI: 10.1109/TTE.2022.3224518

The present paper offers a complete, flexible and adaptable solution for electric vehicles industrial developers to test their designs from all the perspectives required by a V-mode development approach. Construction of high accuracy mechanical and electrical real-time digital-twin models fuzzing dedicated software was proven to be the proper solution to reach results confirmed by actual measurements. Methods for transitioning from real-time simulations to emulations or hardware in the loop testing are presented in detail. The digital-twin solution performing real-time simulations are considered to be the virtual test facility presented in the paper. For actual validation, preliminary the battery is studied via hardware emulation and hardware testing. The same approach is then applied to the vehicle motor together with its electronics and control. The added value of the paper is brought by several aspects such as the real-time co-simulation, performed using National Instruments VeriStand software aggregator, the methods of virtual, emulation and hardware testing of the same assemblies, all being confirmed by comparative analysis. The increased precision obtained, proved by actual measurements, estimates the value and usefulness of this study for those working in electric vehicles development. The content of the paper is an extended genuine study giving hands-on solutions for different types of approaches when it comes to developing and testing mechanical or electrical assemblies. The paper gives a theoretical background pushed to the application side confirmed by actual laboratory testing.