Test bench for converters reliability studies for EV and HEV electrical vehicle applications

In this paper a test bench will be detailed in order to verify the reliability of new inverter prototypes for future EV and HEV electric motors. Cycling tests must be carried out in order to test the reliability of new components for inverters in the same conditions as in real vehicle. A test bench using 20-30 kW induction motor or brushless DC machines has been used. These machines are coupled with a DC motor in order to impose the load torque. Various mission profiles (ARTEMIS cycles) have been implemented in order to impose a load torque on the system for various real driving conditions (urban, jam, road and highway). Control system has been designed using the DS1005 board system from dSPACE. Due to the future development of hybrid electrical vehicles, it will be necessary to integrate power converters as closed as possible to the ICE (Internal Combustion Engine). So very high temperature will be imposed to electronics components (higher than 120degC). New packaging components have been designed by OEM Valeo and will be tested in real conditions on this testbench. Artemis cycles which define vehicle behaviour on different speed-torque conditions (highway, road, traffic jam and urban) are translated to inverter current stresses.