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Testing hybrid and electric vehicles

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Systems integration, diagnostics and testing for electric vehicles

BOSMAL’s offer

  • Projekt i wykonanie konwersji pojazdów spalinowych na pojazdy z napędem elektrycznym dla małoseryjnej produkcji
  • Dobór komponentów układu napędowego i układów uzupełniających (silnik z falownikiem, bateria, system ładowania, przetwornice napięcia, elektryczne elementy grzewcze, sprężarka klimatyzacji, pompa podciśnienia)
  • Dobór i zabudowa systemów wspomagających, takich jak systemy fotowoltaiczne dla pojazdów samochodowych, transmisja danych z pojazdu do zewnętrznych układów rejestrujących
  • Opracowywanie algorytmów układu sterowania wybranymi komponentami pojazdu o napędzie elektrycznym, projekt i wykonanie ECU sterującego systemem napędu elektrycznego i elektrycznych układów wspomagających.
  • Opracowywanie protokołu komunikacyjnego i konfiguracja sieci CAN, opracowanie protokołów diagnostycznych
  • Projektowanie i programowanie systemów HMI w oparciu o wyświetlacze 5 i 7 calowe z funkcją touchscreen
  • Opracowywanie systemów fotowoltaicznych dla pojazdów
  • Niezależne systemy zarządzania podsystemami elektryczno-mechanicznymi pojazdu i dostępu do baterii trakcyjnej (wykorzystanie energii baterii do zastosowań innych niż napędzanie pojazdu)
  • Projekt i wykonanie wiązek elektrycznych oraz modyfikacje wiązek pojazdu bazowego
  • Integracja systemu sterowania z udziałem dostawców głównych komponentów, takich jak silnik i układ bateryjny
  • Diagnostyka pojazdów elektrycznych i ich komponentów składowych
  • Kompleksowe badania pojazdów elektrycznych w tym na potrzeby homologacji (produkcji małoseryjnej).

Prototype – electric car BOSMAL 500 E

Key parameters:

  • three-phase synchronous electric motor PMSM type
    • max. power: 57 kW
    • max. torque: 220 Nm
  • battery: Li-lon type/ ca. 15 kWh
  • single-speed transmission
  • range acc. to NEDC: ca. 100 km
  • maximum speed: 120 km/h
  • charging time: 6 h (single-phase) or 3 h (three-phase)
  • vehicle weight: 1100 kg

Oferta BOSMAL w zakresie badań pojazdów elektrycznych

  • road tests of functionality and durability under various traffic and climate conditions,
  • measurements of geometric dimensions,
  • evaluations of cars in terms of security,
  • evaluation of traction performance (maximum speed, acceleration capacity from a standstill or from a specific starting speed),
  • evaluation of operating properties (vehicle range on different routes, with various driving styles, at sub-zero temperatures),
  • tests of the influence of ambient temperature (low, ambient, high) on the efficiency of the electrical energy storage system, its processing system, the mechanical efficiency of the transmission, and the range and performance of the entire drivetrain,
  • evaluation of steerability and stability of the vehicle on the road,
  • brake assist and steering system assessment and their activation without assist,
  • assessment of ventilation and heating systems’ efficiency,
  • determination of road load factors via the coast down method,
  • measurement of vehicle range on electrical power, at different (non-standard) ambient temperatures,
  • measurement of electricity use at various (non-standard) ambient temperatures,
  • measurement of power at the car wheels provided by the electrical energy supply system,
  • tests of battery charging time,
  • evaluation of the amount of batteries power failure while the vehicle is stopped at negative and positive ambient temperatures,
  • measurements of temperatures of motor and batteries parts while the vehicle is in motion,
  • test result evaluations,
  • other tests and R&D activities.

Electric vehicle range determination

Measurements of the range of vehicles powered by electric drivetrains conducted on the chassis dyno

The measurement method for determining the range of vehicles equipped with an electric powertrain (or vehicles with hybrid electric drive with external charging) is described in UNECE Regulation No. 101.

Measurements include:

  1. initial charging of the battery
  2. performance of the cycle and measurement of the range under electric power

Regulations

  • UNECE Regulation No. 101 and EC Regulation No. 715/2007 – No. 692/2008
  • Regulation (EU) 2017/1151 as amended up to Reg. (EU) 2018/1832

Devices

  • Chassis dyno – AVL Zoellner 4WD
  • Chassis dyno – AVL Zoellner 2WD

Electric vehicle range measurements in road tests

  • BOSMAL conducts range measurements on vehicles on a given route and with specified load
  • Automotives, trucks and buses with electric or hybrid drive are tested

Measurement of electric vehicles’ electricity consumption

Measurement of electric vehicles’ electricity consumption on a chassis dynamometer

The electric vehicle’s electrical energy consumption test is carried out at an ambient temperature of 20°C to 30°C. The study includes the following stages:

  • Initial recharge of the battery
  • A double implementation of a driving cycle of four elementary urban cycles and an extra-urban cycle
  • Recharging the battery

Regulations (applies to tests on a chassis dynamometer)

  • UNECE Regulation No. 101 and EC Regulation 715/2007 – EC 692/2008
  • UNECE Regulation No. 83 and EC Regulation 715/2007 – EC 692/2008
  • Regulation (EU) 2017/1151 as amended up to Reg. (EU) 2018/1832

Devices

  • Chassis dynamometer – AVL Zoellner 4WD
  • Chassis dynamometer – AVL Zoellner 2WD
  • Power analyser – HIOKI 3390

Badania zużycia energii elektrycznej pojazdów elektrycznych w szerokim zakresie temperatur – badania rozwojowe

Badanie zużycia energii elektrycznej pojazdu elektrycznego są też prowadzone w Instytucie w szerszym zakresie temperatur tzn. od -35 do 60°C dzięki naszej infrastrukturze:

  • Komora klimatyczna WEISS WK 643’/ -35°C do +60°C
  • Hamownia podwoziowa – AVL Zoellner 4WD

Więcej na stronach:

  • Badania dynamiki pojazdów na hamowniach podwoziowych 2WD i 4WD
  • Pomiary dynamiki pojazdów w temperaturach z zakresu od -35˚C do 60˚C

Measurement of energy consumption in electric vehicles during road tests, SORT

  • Determination of electric energy consumption in vehicles under real-world driving conditions
  • Aut omobiles, trucks, buses with electric or hybrid powertrains
  • Measurements of electric energy consumption during the SORT (Standardised On-Road Tests) drive cycle -buses
    • Complete data recording and measurement for battery charge and discharge
    • Inverter and Drive Circuit Efficiency Measurement
    • Vehicle Energy Consumption in steady and transient states
    • Circuit Harmonics Measurement

Na zdjęciu: Miernik energii elektrycznej HIOKI 3390 i Czujnik cęgowy HIOKI CT6845-05

Miernik energii elektrycznej HIOKI 3390 i Czujnik cęgowy HIOKI CT6845-05

Exhaust emission and fuel consumption tests of hybrid vehicles (including charge balance)

Vehicles equipped with a hybrid electric drive system are to be tested according to the applicable regulations for vehicles with an internal combustion engine. Two tests are conducted, under the following conditions:

Condition A: test is conducted with a fully charged energy storage device.
Condition B: test is conducted using a minimally charged energy storage device (in its state of maximum discharge capacity).

Exhaust emissions are analysed according to the version of UNECE Regulation No. 83 in force at the moment of vehicle homologation. A power analyser, placed between the energy source (wall socket) and vehicle charger, measures the charging energy e [Wh] delivered from the power supply network. CO2 emissions and fuel consumption measurement, including the charge balance computation and correction is presented in UNECE Regulation No. 101.

Badanie emisji spalin, zużycia paliwa i zużycia energii elektrycznej samochodów hybrydowych
Badanie emisji spalin, zużycia paliwa i zużycia energii elektrycznej samochodów hybrydowych

Regulations 

  • UNECE Regulation No. 101 and EC 715/2007 – EC 692/2008
  • UNECE Regulation No. 83 and EC 715/2007 – EC 692/2008
  • UNECE Global Technical Regulation (GTR) No. 15
  • UNECE Regulation No. 168/2013
  • UNECE Regulation No. 134/2014
  • UNECE Global Technical Regulation (GTR) No. 2
  • Regulation (EU) 2017/1151 as amended up to Reg. (EU) 2018/1832

Laboratory No. 1

  • Exhaust gas analysis system – AVL AMA i60 D1 LE
  • Emissions collection system – AVL CVS i60 LD LE
  • Particulate sampling system – AVL PSS i60 SD
  • Solid particle number counter – AVL 489 APC plus
  • Climatic chamber from +14 to +30°C
  • AVL 2WD chassis dyno
  • HIOKI 3390 power analyser with clamps

Laboratory No. 2

  • Exhaust gas analysis system – HORIBA MEXA 7400 HTRLE
  • Exhaust gas analysis system – HORIBA MEXA 7500 DEGR
  • Emissions collection system – HORIBA CVS 7400 S
  • Particulate sampling system – HORIBA DLS 7100 E
  • Solid particle number counter – HORIBA MEXA-2000SPCS
  • Climatic chamber – WEISS WK 643’/35-60/Ro, temperature range from -35°C to +60°C
  • AVL 4WD chassis dyno
  • HIOKI 3390 power analyser with clamps

Electric vehicles charging stations, DC – 50 kW and AC – 22 and 43 kW chargers

Quick-charging station – Efacec EV DC QC45

Efacec EV DC QC45 chargers are solutions that allow fast supply of energy to any type of vehicle, regardless of the standard: CHAdeMO, CCS or AC Type-2. The system is extremely easy to use. After identification of the user (authorization – if required), you only need to select the option applicable for a given vehicle type and connect the charger. The DC charging mode will end automatically or it can be stopped on demand by the user. Optional connectors: Basic Single DC, Dual DC and even Triple DC+AC can have a single enclosure or can be split as separate cables connected to the common interface. QC45 combines a unique design and excellent specification – high performance, optimum power ratio and efficiency.

Stacja szybkiego ładowania - Efacec EV DC QC45

Quick-charging station – system overview

  • 0 to 80% in less than half an hour
  • Quick charging of any compatible vehicle
  • Simultaneous charging with DC and AC
  • Color display
  • Multi-standard (DCA – CHAdeMO; DCC – CCS/Combo; AC)
  • Network integration (OCPP or via a dedicated protocol)
  • Communication (3G, LAN, Wi-Fi)
  • Optional 2-element configuration (kiosk/terminal)
  • Support for many connector standards
  • DC up to 50 kW
  • AC up to 43 kW
  • High efficiency: > 93%
  • High power ratio: 0.98
  • Plug & play type system
Stacja szybkiego ładowania - Efacec EV DC QC45

AC charging station – for testing vehicles

AC charging station for electric vehicles with type 2 sockets. AC charger allows simultaneous charging of two vehicles.
Main parameters:

  • socket: type 2 (IEC62196-2) – cable Type2 or Type1
  • output current: 32 A (x2)
  • output power: 22 kW (x2)
  • output voltage: 400 V AC 3P + N + PE
  • charging mode: Mode 3 (IEC 61851)

The station is used to charge vehicles tested at the BOSMAL Institute.

Stanowisko ładowania AC

Tests of batteries and heating and air conditioning systems installed in electric vehicles at temperatures from -45°C to 75°C

  • Zakres temperatur od -45°C do 75°C
  • Określenie czasu rozładowania baterii dla różnych temperatur otoczenia
  • Określenie zdolności i czasu ładowania baterii w różnych temperaturach otoczenia
  • Badania układów ogrzewania i klimatyzacji wnętrza w różnych temperaturach otoczenia

CO₂ emission and fuel consumption testing (including consideration of the power balance)

  • CO2 emission and fuel consumption measurement using the carbon balance method.
  • Power balance measurement and consideration of that parameter in the final CO2 and fuel consumption result.
  • Measurement over various driving cycles, such as: NEDC, WLTC, FTP-75, HFET, JC08, WMTC, according to the requirements within in applicable European, American and Japanese regulations.
WLTC, NEDC

Regulations

  • UNECE Regulation No 101 and Regulation EC 715/2007 – EC 692/2008
  • UNECE Global Technical Regulation (GTR) No. 15
  • Japanese Regulation TRIAS (99-006-01)
  • US EPA CFR Title 40
  • Regulation (EU) 2017/1151 as amended up to Reg. (EU) 2018/1832

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