Siemens Solutions for Test Equipment

Ulrich Weinhart

Unrestricted © Siemens 2016 All rights reserved. www.siemens.com/teststands

Test Stands
Large variety with many different requirements

• Engine • Special Test Stands

• Cold test stand • Brake
• Hot test stand • Drive shaft
• Transmission • Balancing machines
• Manual transmission • Tire testing machines
• Automatic transmission • Wheel
• Differential • Component
• Transfer case • Fatigue
• Hybrid transmission
• Roller Rigs
• Noise, vibration, harshness (NVH)
• Performance

Page 2 October 10, 2016 Siemens Solutions for Automotive Testing

X-Test Stands
Market requirements

Where do Testing
•
Energy exchange in the Computer inter- Energy recovery for braking
Machines Make the common DC bus at multi- connection for long time applications without harmful
Highest Demands? axis test stands data acquisition current harmonics
• Drives
• Inverters High dynamics e.g. for Control systems for rotating
• Communication simulation of combustion field frequencies about
engines 1,000 Hz
• Control systems
• Planning
• Commissioning Integrated safety Integration of modern
functions e.g. SLS for simulation tools like Matlab
Key requirements? entering the test cell or LabVIEW
• Accuracy
• Repeatability
Adaptable control system Integrated battery Speed and torque
• Safety for the highest torque simulation constancy (no ripple)
• Flexibility quality

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Value-Add for Test stand manufacturer

Planning Phase Engineering Phase

• Drive Line Dynamic Analysis • Openness for External Set Point Sources
• Knowledge of bending critical speed in real • Efficient integration of customer models of
construction SINAMICS S120 MATLAB SIMULINK & C++ or LabVIEW

• Multi Body Simulation Open Architecture for

•

• Knowing oscillation Technology Functions

frequencies • Example: combustion engine simulation in
current control clock (e.g. 31.25µs) without
additional hardware
•

Design optimization already in place Customer loyalty through openness

during construction and control performance

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Vibration Analysis during Mechanical Construction
Drive Line Dynamic Analysis

• FEM Determination of Bending Critical Speed • User Benefits

• Performed by Siemens Mechatronic Support • Accuracy of bending critical speed
• Calculation considering the complete system • Design optimization in place during construction
• Long-standing experience • Risk minimization
• By assessing the overall design

Locking Adapter
• Increased machine reliability
Assembly & Rotor
1.6 kg 3.6 kg 770 – 890 mm
Shaft
72.5 mm Xxx kg

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Vibration Analysis during Mechanical Construction
Multi Body Simulation (MBS)

• Calculation of Torsion Oscillations • User Benefits

• Performed by Siemens APC • Definition of oscillation frequencies
• Calculation considering the complete system • Design optimization in place during construction
• Long-standing experience • Risk minimization
• By assessing the overall design
Multi Body
Simulation Model • Increased machine Speed Controlled System
reliability
• Reduction of
commissioning time
• Optimal dimensioning
of entire powertrain
• Less wear

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Periodical Signal Generation
Signal generator as a setpoint
• SINAMICS Setpoint Generator
• Set points are provided in current control clock
• e.g. 31.25µs
• Sinus-, sawtooth- or square-wave signal
• Phase-, frequency- and amplitude correction
possible
• Attain signal frequencies up to 1.6 kHz
Page 7 October 10, 2016
• User Benefits
• Internal drive function
• Usable without a superimposed control
• Very fast setpoint setting
• Connectable as additional torque or additional speed
• Use for periodical disturbance compensation
Siemens Solutions for Automotive Testing
Engine Simulation with Drive
TPS (Torque Pulse Simulation)

• TEC Polygon • User Benefits

• Setpoints are provided in current control clock • Realistic test
• e.g. 31.25µs • No engine conditioning
• Torque profile • Considerable noise reduction
can be
• No fuel consumption
imported
• Attachable torque profiles for
from Excel
different engine types
• Phase and
• Excellent torque precision
amplitude
correction • Usable without superimposed
possible control
• Signal frequencies up to 1 kHz • Very fast setpoint setting
• Torque profile standardized on mechanical angle

Page 8 October 10, 2016 Siemens Solutions for Automotive Testing

Cold Engine Test Stand
Automatic disturbance compensation

• TEC Leco (Learning Error Compensation) • User Benefits

For disturbance compensation of big engine
•
• Few parameter settings necessary
cold test stands • Optimal bad engine recognition
• Self-learning compensation • Fast teaching of new engine types
• Usually learned after 4 – 6 periods • No external measuring technique required
• Quality criterion = a constant speed
• Fault detection over non-periodic
disturbing moment
à Speed deviation

Page 9 October 10, 2016 Siemens Solutions for Automotive Testing

Cogging Torque Compensation (new function module with FW4.8)
Compensation of periodical disturbance torque

• Constant Torque and Speed • User Benefits

• Learning phase for the identification of cogging • Free firmware function
• Pre-control of cogging • Optimal test results
• Periodicity configurable • Constant torque also at low speeds
à external disturbance torque • Reduction of speed ripple in permanent magnet
Stator Core
synchronous motors (PSM)
Magnet

SIMOTICS T
Shaft Synchronous Torque Motors
Coil 1FW3, 1FW6

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Efficient Simulation Engineering
Matlab SIMULINK Interface

Integration of SIMULINK Models

• • User Benefits
in SINAMICS and SIMOTION • Rapid compilation of control structures
• SIMOTION Controller C, D, P • Programming out of the simulation
• P – 250µs
• Free targets for Matlab SIMULINK
• D – 250µs
• Automatic coding
• No C / C++ know-how required
• Optimized workflow
• Time saving by simulated controller
• SINAMICS S120 Drive • Reduction of commissioning time
• CU320-2 – 1 ms • Easy, graphical programming

Page 12 October 10, 2016 Siemens Solutions for Automotive Testing

Efficient Simulation Engineering
LabVIEW Interface

Communication between
• • User Benefits
Standard PC and SINAMICS PC User • Predefined interface
LabView
Program
• Predefined VIs • Fast communication (up to 1ms)
• Standard telegram 1 • Cyclic and acyclic
• Standard telegram 111 Communication communication
• Free telegram Driver • Control of the entire test stand
DLL
via LabVIEW
• acyclic communication
• Standard PC sufficient
PROFINET • Free application download
PROFINET
Device • No control or HMI required
Drive

Peripheral I/O

SINAMICS G / S

Page 14 October 10, 2016 Siemens Solutions for Automotive Testing

PROFINET IRT Driver
For third parties

Realization of PROFINET
• • User Benefits
for Data Logging and • Reduction of interface converters
External Control Systems
• No EMC influences
• PROFINET isochronous (IRT) for cycle
• Use of industry standards
times up to 250 µs
• Broad base of manufacturers
• Ring topology for higher
equipment availability • Simple integration

• Software development kit • High performance due to rapid memory

available access
• Includes source code • Consistent process data
• For different operating
systems
• CP1616 (PCI) or
CP1604 (PCI-104)

Page 15 October 10, 2016 Siemens Solutions for Automotive Testing

PROFINET IRT Controller Solution
Hilscher netX

Realization of PROFINET
• • User Benefits
IRT Controller on own systems • Line-, tree- and ring topology (planned)
• PROFINET (IRT) for cycle times up to 250 µs • Consistent process data
• PROFINET IRT Controller for Hilscher Master
Technology available
• For PC card, embedded module and ASIC for
integration
• Independent configuration with
SYCON.net

Hilscher IRT

Page 16 October 10, 2016 Siemens Solutions for Automotive Testing

Constant Torque and Speed
Torque transducers using PROFINET

HBM Test and Measurement

• • User Benefits
Kistler Instrumente AG • No EMC problems
• Construction of closed loop controlled systems • Due to digital signal
about SINAMICS standard communication • Short controlled systems
• Up to 1ms cycle time with PROFINET RT • Due to no additional signal converting
• Up to 250µs cycle time with PROFINET IRT • Realization of fast controlled systems

Page 17 October 10, 2016 Siemens Solutions for Automotive Testing

SINAMICS S120 Drives
For high-end test system applications

• Modular Multi-Axis Drive System • User Benefits

• Power range 0.12 – 5,700 kW (0.16 – 7,500 HP) • Unified system
• Servo / Vector control, V/f • Energy saving by common DC-bus
• PROFINET, PROFIBUS, EtherNet/IP, CANopen, • Excellent torque
Ethernet, RS232/485, Pulse-direction interface, precision
USS à saving torque
• Controlled rectifying unit, set up controller transducers
• Water and air cooling
• 380V-480V (50-60Hz), IT system qualified
• Safety Integrated (STO, SS1, SBC, SOS, SS2,
SLS, SSM, SBA, SDI, SLP) – acceptance report
integrated in STARTER
• Position functionality
• Pulse frequency up to 32 kHz

Page 18 October 10, 2016 Siemens Solutions for Automotive Testing

SINAMICS S120 HFD
High Frequency Drive

• Sinamics S120 HFD • User Benefits

To be able to combine the high power with high speeds, the
innovative material silicon carbide is processed for the
diodes. In that way, the low-loss switching of big currents is
possible without derating.
• High output power at simultaneously very high
output frequency/-speed
• Hardly harmonic wave load in the motor based on
a sinusoidal output voltage

Silicon Carbide – Advantages at a glance

• Operation of low inductive motors
In comparison with conventional silicon semiconductors,
silicon carbide semiconductors offers convincing
advantages:
• 70% lower switching losses
• 4 times higher switching frequency

Page 19 October 10, 2016 Siemens Solutions for Automotive Testing

Safety Integrated
What makes Siemens first worldwide in machine safety?

• Safety Integrated means

The drive monitors autonomously or in combination with a
•

PLC the motor and maintains a safe process status.

Safety functions integrated in the drive ensures that, in
case of an emergency stop signal, e.g. via an emergency
stop switch or a bus signal, the motor is safely stopped
by the drive

• Safety Functions Integrated in SINAMICS

• Safe Torque Off (STO)
• Safe Stop 1 (SS1)
• Safe Brake Control (SBC)*
• Safely Limited Speed (SLS)**
• Safe Direction (SDI)**
• Safe Speed Monitor (SSM)**
• Safe Operating Stop (SOS)**
• Safe Stop 2 (SS2)**
• Safe Brake Test (SBT)**
• Safely-Limited Position (SLP)**
• Safely Position (SP)**

• Encoderless Safety
Several safety functions are provided, for which no failsafe or several
•

standard encoders need be used

• * Applies only to Blocksize and Booksize devices
Page 20 October 10, 2016 • ** In connection with sin/cos encoder Siemens Solutions for Automotive Testing
SIZER
Tool for configuration of motors, drives and control units

Fast Dimensioning
• • User Benefits
— From the Requirement to the Solution • Configuration guaranteed by technical
• Guided configuration by deposited mechanical systems evaluation of the application
• Integrated database with all motors and drives • Fast selection of drive components
• Integrated dimensional drawing generator • Free download
• Mechanical rack system, wiring diagram, • Web version online
and parts list
• System reaction consideration
• Thermal analysis of the application
• Consideration of pulse frequency, dynamic,
system effectiveness, supply fluctuations,
traversing profiles and mechanical counter torque
• Performance evaluation of the control unit
• Support of different grids

Page 21 October 10, 2016 Siemens Solutions for Automotive Testing

Motors for Test Stands
SIMOTICS spectrum

SIMOTICS M 13 12,435 Nm
Asynchronous Main
1PH8 2,800 20,000 rpm

SIMOTICS T 100 7,000 Nm

Synchronous Torque
1FW3 150 1,700 rpm

SIMOTICS T 22 5,760 Nm
Synchronous Torque
1FW6 38 940 rpm

Test Stand 200 1,000 Nm

Motors
1SR9 7,000 10,000rpm

WEISS Special 100 Nm 6,000 Nm

Spindle Motors
2,000 42,000 rpm

Nominal torque
Nominal speed

Page 23 October 10, 2016 Siemens Solutions for Automotive Testing

Motors for Test Stands
SIMOTICS M main motors

1PH8 1PH8

Features Optimized for converter-fed operations, high maximum speeds, low Optimized for drive-fed operations, high
dimensions maximum speeds, low dimensions,
reduced sound pressure level

Cooling Method Air Water

Degree of Protection IP55 IP23 IP55 / IP65

Nominal Power PN 2.8 – 730 kW 20.5 – 1,340 kW 3.5 – 460 kW

(3.75 - 975 HP) (27.5 - 1,800 HP) (5 – 615 HP)

Nominal Speed Nn 2,800 – 20,000 rpm 2,800 – 7,500 rpm 3,300 – 20,000 rpm

Nominal Torque MN 13 – 6,860 Nm 370 – 12,435 Nm 20 – 2,610 Nm

Page 24 October 10, 2016 Siemens Solutions for Automotive Testing

Motors for Test Stands
SIMOTICS T synchronous torque motors

1FW3 1FW6

Features The torque motor for applications with the highest The built-in torque motor for applications with the
torques highest torques and high precision

Cooling method Water cooled and self cooled Water cooled and self cooled

Shaft types Hollow shaft Solid shaft Insert shaft —

Nominal power PN 2.8 - 380 kW 1.7 – 54.1 kW

(3.75 – 510 HP) (2.52 – 72.5 HP)

Nominal speed nN 150 – 1,200 rpm 38 - 940 rpm

Nominal torque MN 100 – 7,000 Nm 22 – 5,760 Nm

Page 25 October 10, 2016 Siemens Solutions for Automotive Testing

Motors for Test Stands
A motor developed specifically for test stand applications

Test Stand Motor

1SR9

Features Optimized for engine test stands, low inertia

Cooling Method Forced ventilated

Degree of Protection IP23

Nominal Power PN 110 – 450 kW

(150 – 605 HP)

Nominal Speed nN 7,000 – 10,000 rpm

Nominal Torque MN 200 – 1,000 Nm

Page 26 October 10, 2016 Siemens Solutions for Automotive Testing

Motors for Test Stands
Specialized motors

Weiss Spindles SIMOTICS L Linear Motors

1FEx 1FN3

Features Optimized for drive-fed operations, high maximum speeds, Linear motors for applications with highest dynamic
small motor dimensions, reduced sound pressure level, and precision
highest dynamic, customized, SMI24

Cooling Method Water Water

Degree of Protection IP55 / IP65 IP23 / 65

Nominal Power PN 50 – 300 kW 1.7 – 81.9 kW

(67 – 400 HP) (2.25 – 110 HP)

Nominal Speed nN 2,000 – 42,000 rpm (Velocity v max) 105 – 836 m/min

Nominal Torque MN 100 – 6,000 Nm (Feed torque FN) 200 – 10,375 N

Page 27 October 10, 2016 Siemens Solutions for Automotive Testing

Powertrain Solution for Hybrid
Battery simulation with SINAMICS components

SINAMICS S120 Drive Motor module Braking Module

Control Line Module Motor Modules
at 0 Hz Common (optional)
3AC 380 – 480 V
50 - 60 Hz Unit up to 1.2 MW up to 800 kW DC Bus
CU320-2

` Battery Simulation

Filter
Isolation
Transformer
e. g. 400 VAC : 400 VACs DC 0 – 690 V max. 1,200 A
(<1% ripple*)
Absorber Power controller of the vehicle

M Drive motor of the vehicle

Load
Under
Test
Transfer gear box of the vehicle

Page 28 October 10, 2016 Siemens Solutions for Automotive Testing

Powertrain Solution for Hybrid
Battery simulation with SINAMICS components – alternative

SINAMICS S120 Drive 5x SINAMICS DCP Braking Module

Control Line Module Motor Modules DC-DC Converters Common (optional)
3AC 380 – 480 V
50 - 60 Hz Unit up to 1.2 MW up to 800 kW DC Bus
CU320-2

` `

Isolation
Transformer
e. g. 400 VAC : 400 VACs DC 0 – 920 V
max. 1,000 A
Absorber Power controller of the vehicle

M Drive motor of the vehicle

Load
Under
Test
Transfer gear box of the vehicle

Page 29 October 10, 2016 Siemens Solutions for Automotive Testing

Test Stand Solution with Energy Storage
Intelligent energy management

SINAMICS S120 Drive Braking Module

3AC 380 – 480 V Control Line Module Motor Module Motor Module Common (optional)
50 - 60 Hz Unit up to 1.2 MW up to 800 kW at 0 Hz DC Bus
CU320-2

Choke

Load
User Benefits Under
Test 0-690 VDC
Absorber
§ Reduction of the transformer
performance
§ Reduction of the line module EDLC – Electrical Double
Layer Capacitors
§ Environmental protection by an
intelligent energy management

Page 32 October 10, 2016 Siemens Solutions for Automotive Testing

Roller Rig
NVH or Performance test stand

SINAMICS S120 Drive

Common Braking module
3AC 380 – 480 V DC Bus (optional)
50 - 60 Hz

User Benefits Roller Rig

§ Compact style by direct motors

§ Noise minimization by water 1FW3 1FW3
cooling and variable switching
frequency
§ Drive integrated gearing
§ Energy exchange with 1FW3 1FW3
common DC Bus

Page 33 October 10, 2016 Siemens Solutions for Automotive Testing

Test Stand Solution with Energy Storage
Intelligent energy management (UL concurring)

Control Unit 320-2 Control Unit 320-2

Common DC Bus
Line Module up to MoMo up to 800 kW Capacity module 132mF (up
600-720VDC
3AC 380 V – 480 V 1,2 MW to 18 pieces) ALM + AIM
50 - 60 Hz

…..n

3AC 380 V – 480 V

Absorber 50 - 60 Hz

User Benefits
§ Safe operation of the test bed also at short grid interruptions and external disturbances
§ Reduction of the transformer performance and energy costs
§ Effective dimensioning of strongly cyclical drive systems
§ Reduction of the line module
§ Environmental protection by an intelligent energy management
§ Easy installation by insertion technique
§ 6SY7000-0AE64 Sinamics Capacity module 132mF

Page 34 October 10, 2016 Siemens Solutions for Automotive Testing

Thank You

• Ulrich Weinhart
• Siemens Digital Factory

• Phone +49 (9131) 98-47115

• Cell +49 (174) 3128097
• E-Mail: ulrich.weinhart@siemens.com

www.siemens.com/teststands

Page 35 October 10, 2016 Siemens Solutions for Automotive Testing