No car? No problem! Multibody dynamics enables cyber-physical tests of ePowertrain motors at Universidade da Coruña

The Mechanical Engineering Laboratory (LIM) at the Center for Research in Marine and Industrial Technologies (CITENI), part of the Industrial Campus of Ferrol at the University of A Coruña, has partnered with GKN Driveline Zumaia to revolutionize ePowertrain motor testing. Using advanced multibody dynamics simulation, they have developed a methodology to conduct essential motor tests without physical full-vehicle prototypes.

Overheating is a critical issue for ePowertrain motors, as excessive temperatures can cause irreversible damage. The traditional characterization of their response and their thermal dynamics when they are mounted on a particular vehicle would require extensive and costly test campaigns, which are time-consuming and expensive.

Together, LIM and GKN have created an innovative setup that interfaces the eMotor with a model-based multibody dynamics simulation of the vehicle. This can be driven by a human or an automatic driver, replicating a wide range of driving conditions.  The key benefits of this solution are:

•            Cost and time efficiency: Lab-based tests decrease the need for expensive and lengthy circuit campaigns.

•            Safety and replicability: Controlled lab environments reduce risks and ensure precise, repeatable conditions.

•            Versatility: Easily replaceable vehicle models allow for varied scenarios without multiple full-system prototypes.

•            Advanced sensor integration: Enables the use of sensors that are difficult to deploy in physical vehicles.

•            Integration with digital twins and visualization: The test bench can be combined with a digital twin of the tested motor to determine the thermal operation point of the device. An intuitive visualization tool provides real-time feedback to the test bench users.

This approach promises to streamline testing processes and set new standards for safety, efficiency, and precision in ePowertrain motor evaluation, potentially serving as a model for future electric vehicle technology research and development.

For more information, please contact the Mechanical Engineering Laboratory at CITENI, University of A Coruña:

E-mail: f.gonzalez@udc.es
www: https://lim.ii.udc.es/contact.es.html