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Electric Vehicle Test Cell Control and Data Acquisition System

A complete off-the-shelf solution for deterministic real-time testing of components or full vehicle eDyno. 

Benefits

 

  • Low-cost entry-level.
  • The open platform provides greater modularity, flexibility, model integration and custom sensors.
  • Quick and easy to deploy, configure and replicate.
  • Reduce cost and complexity with a future-proof platform.
  • Achieve complete test coverage with a flexible platform.
  • Enable accurate and innovative powertrain test systems.
  • Achieve faster development times with automation and collaboration.
  • Adaptable to rapidly accommodate changing project requirements.
  • Independent review of requirements and outsourced testbed completion.
  • Integration with existing systems.
  • Detect defects earlier through scalable testing.
Example UI

System Overview

The world global Electric Vehicle (EV) market is increasing rapidly. By 2040 55% of all new car sales and 33% of the global fleet will be electric.

This rapid rate of development combined with new and emerging technology implementations and complexity is driving increased demand for new test systems and architectures. Test cells require a much more modular approach; combining standard frameworks and commercial–off-the-shelf (COTS) hardware this Test Cell Control and Data Acquisition System provides a low-cost route to a reconfigurable, flexible, modular, expandable solution.

The EV Test Cell Control and Data Acquisition System is a complete, off-the-shelf solution for either real-time component testing or full vehicle eDyno testing. The system has been designed with a deterministic real-time test engine at its heart, to ensure that the system can run high-speed models and close the loop with real sensor data at rates upwards of 1 kHz.

With the National Instruments hardware and software platform at its core, the system has also been designed with maximum flexibility and extensibility in mind.

The modular system comprises

  • Test Cell Control and Data Acquisition Software Platform.
    EVolution Electric Vehicle Test Cell Control and Data Acquisition System and Power Analyser Rack

    Example Test Cell Control and Data Acquisition System and Power Analyser Rack

  • Configurable Test Cell Control and Data Acquisition Hardware.
  • A range of optional support services to get your test cell up and running fast:
    • Consultancy
    • Test Cell Integration
    • Cell Services Integration
    • Safety System Integration
    • Power Analyzer Rack
    • Data Management including Enterprise Integration
    • Data Analysis.

Key Features

High-speed deterministic modelling and control. (HiL)

The software provides the ability to run many different types of models, ranging from MATLAB/Simulink, AVL Boost and Cruise, TechnaliaDynaCar, IPG CarMaker to simple models built in LabVIEW or pure C code.

Intuitive test sequencing and scripting via Python scripting engine.

No need for high-level programming experience. Predefined test-steps for configuration and test profile creation. Integrated Python scripting tool allows new steps to be created for applying calculations to channels, importing new file formats and other requirements.

Multi-link capability

Multi-link capability- deterministic high-speed data sharing between multi-axis or systems for maximum scalability to facilitate multiple test applications.

USER LEVEL BASED ACCESS

Multiple Configurable User Access Levels ensure ease of use,  extensibility, system security, and allow new scripts and testing sequences to be generated and low-level functionality increased.

Channel mapping with calibration and alarming.

Assign specific physical channels to in ports and out ports in models. Name channels appropriately for your specific test. Apply scaling and calibration for your sensors.

Open extensible architecture.

Based on NI PXI modular hardware platform offering a cost-effective, adaptable solution for changing hardware requirements. Flexible to accommodate new technologies and extendable chassis for increased demands. Add new sensors, or bespoke protocols via a simple low-cost, ‘plug-in’ upgrade. 

Data-logging

All Data is synchronised, time-stamped and logged to TDMS file format. Plug-ins are available for both MATLAB and Microsoft Excel™.

Dynamic User Interface

Configure and save user interface in the test. Create profiles specific to your requirements. No need to restart the test.

Signal isolation.

Optional galvanic isolation provided via the Test Cell Management Unit.

As part of the NI ecosystem of solutions, the system is able to integrate with the wide range of commercial-off-the-shelf ADAS solutions, and expertise developed and supported by the National Instruments community of Alliance Partners.

TEST CELL CONTROL AND DATA ACQUISITION SOFTWARE PLATFORM

The advanced software is designed to address many of the issues faced by a busy and technically demanding test environment including powerful features to support efficient test configuration and deployment:

  • Intuitive user-friendly interface and workflows.
  • The ability for high speed synchronous data acquisition and logging (up to 200kHz – requires specific hardware options/support).
  • Standard 1kHz loop rate for model execution, IO update rates and data logging.
  • Flexible to support multiple high-speed deterministic model formats including MATLAB/Simulink, AVL Boost and Cruise, TechnaliaDynaCar, IPG CarMaker, LabVIEW, as well as less demanding applications e.g. battery test. Simply import new models as compiled DLL and map inputs and outputs.
  • Simple and fast to deploy standard scripts or create new scripts via Python scripting tool and support library.
  • Supports long continuous test durations with a built-in real-time sequencer (when based on headless real-time system). 
  • Change and manage test cell configurations from a single interface.
  • User level-based access.
  • A dynamic user interface that can be reconfigured in tests removing the need to restart.
  • Open extensible architecture. Add new sensors or bespoke protocols via a simple low-cost, ‘plug-in’ upgrade or import via built-in template. The new custom device is automatically verified, packaged and deployed down to the real-time controller.
  • Wide range of standard comms buses are supported such as High Speed CAN bus up to 1 Mbits/sec, Ethernet up to 1000BASE-T, Generic RS-232, EtherCAT, CANopen, Profibus, FlexRay, LIN (please note that many of these require specific interface cards).

APPLICATION SPECIFIC IMPLEMENTATION

The software offers a number of implementations to ensure application-specific optimisation.

Example user interface

Cell Configuration

Custom Device Management

Optional Test Cell Management Unit

Dynamic user interface and widgets

Python Scripting Tool

Example DAQ unit and Power Analyser Rack

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