MR2 Hardware-in-the-loop applications
Auto-test of motor drive
To improve the product quality, higher test coverage is really important. The higher the test coverage, the more expense is increased without test automation. MR2 can be easily accessed via MODBUS by a communication module, and integrated to a management system where a controller under test is also connected via communication. That makes your test easy and safe.
Power train control verification of electric car
Three major parts in the real time emulation of an electric car are: 1. vehicle dynamics and driving conditions, 2. the power train (traction force), 3. the motor drive controller. In this case, the CarSim is for first part and the model is downloaded to an RT target; the traction force is the electric torque from the motor in MR2 HIL; the functioning of the motor in MR2 is driven by a real motor drive controller, which is the Hardware Under Test. This real time emulation can be used for testing and verification of the ECU of an electric car. Very powerful, easy-to-use, and low cost.
Motor drive development
MR2 receives the gate driving signals (usually PWM signals) from the motor drive control board, calculates the motor states, including phase currents, rotor position/speed etc., and then outputs all the information to monitor or back to the motor drive control board immediately. The "brain" of the motor drive is deceived as functioning with real power stage and motor. Such that a lot of debugging and tuning can be done efficiently, time and power saving.
Power train control verification of electric motorcycle
Similar to electric car application, the real time emulation system for power train control verification can be switched to electric motorcycle by changing the physical model, which is modeled by the BikeSim. As you can see in the video clip, the driving process of an electric motorcycle, such as uphill and downhill, the motor and motor drive will respond accordingly.
Digital twin of crane system
In addition to motor drive development, more applications are capable by inputting the external load torque from the extension terminals of MR2. In this case, we construct a crane model which is driven by a electromagnetic torque of a motor from MR2, and feed the load torque computed by the crane model back to MR2. This real time emulation is exactly one example of the Digital Twin. With the Digital Twin of crane system, the swing suppression is designed to regulate the speed command to motor drive which drives the motor in MR2. The crane controller tuning coupled with motor drive and motor dynamics is easily constructed in the laboratory. This is the most common and practical application of Digital Twin.
Motor parameters variation during operation
MR2 can modify all system parameters on-line, so it can simulate the change of parameters during system operation. The most practical example is the case where the resistance of motor increases due to temperature rising, and the control performance is reduced accordingly. In this case, the customer constantly increases the rotor resistance of the induction motor during the system operation to simulate the effect of temperature rising. It can be clearly seen that the deviation of the magnetic field orientation caused by the change of the rotor resistance causes the control efficiency to decrease (larger phase currents and lower accuracy of speed control).