Charged EVs | Electrifying Auxiliaries: A versatile system method for a number of auxiliaries

Charged EVs | Electrifying Auxiliaries: A versatile system method for a number of auxiliaries


Sponsored by KEB

Historically, a combustion engine offers extra than simply traction energy to the wheels for industrial autos. It powers smaller auxiliary hundreds from the drive belt resembling the ability steering pump, air compressor for brakes and suspension, HVAC compressor, and coolant pump. And for physique tools, an engine offers energy by way of PTO to bigger hundreds resembling hydraulic pumps. However electrical autos with a propulsion motor that aren’t always operating means the auxiliaries have to be independently managed.   

Whether or not it’s a supply van, bus, heavy-duty truck, or cellular equipment, all of those automobile sorts will possible have a number of auxiliaries. Moreover, autos may have variable configurations of apparatus. KEB presents a versatile system method to affect a number of auxiliaries with the T6 Auxiliary Inverter. This paper examines every product characteristic and showcases the worth it has for designers and system integrators.

Scalable and Modular {Hardware}

To assist a number of auxiliaries, the T6 Auxiliary Inverter is designed to be a scalable and modular “system” answer. The system consists of a number of inverter output levels contained inside a single housing. Which means one excessive voltage DC enter provide to the system, one set of coolant plumbing connections, and one set of low voltage management connections. From a scalability standpoint, the T6 system may be scaled from a single inverter output to a most of six impartial AC motor management outputs. And from a modularity standpoint, every inverter module has an influence ranking choice of seven.5kW (16.5A), 15kW (33A) or 30kW (60A). Thus, there are 83 potential {hardware} system configurations.  

For multi-axis techniques, there are a number of advantages to contemplate:

Lowered elementsIn contrast with individually distributed inverters models for every auxiliary, a multi-axis system answer reduces redundant elements resembling DC cables, DC fuses, coolant plumbing, and low voltage wiring harnesses. A discount within the variety of elements results in a cleaner structure, a smaller footprint, much less weight, fewer potential factors of failure, decrease upkeep, and a simplified set up course of. 

Lowered priceAlong with decreasing the whole techniques price by eliminating redundant elements, a multi-axis unit itself turns into more and more cost-efficient because the variety of output modules will increase. That’s, the marginal price so as to add further energy modules to a system goes down. Thus, a multi-axis inverter turns into a very enticing funding when controlling greater than two auxiliaries. 

Versatile set up – The T6 Auxiliary Inverter does NOT have to be put in close to the auxiliary motor. This flexibility is essential the place area is restricted. Motor cable lengths as much as 30 meters have been examined and permitted, permitting the inverter to be distant mounted from the auxiliary motor. That is potential since electromagnetic compatibility (EMC) was given consideration within the design phases, resembling built-in DC choke filters to mitigate electromagnetic interference, connector shielding and clamping, and shifted IGBT switching. Moreover, the T6 housing is IP67-rated for environmental circumstances and subsequently appropriate for exterior mounting, such because the chassis body or elsewhere on the automobile.  

Versatile Motor Management Options

Since auxiliary motors come in numerous sorts, the T6 Auxiliary Inverter offers versatile choices to manage all forms of AC motors with strong management and straightforward start-up. The supported motor sorts embrace induction motors, everlasting magnet synchronous or servo motors, and synchronous reluctance motors which may be operated in velocity, torque, or positioning management modes. All of those motor sorts and management modes can function with sensorless motor management.

Sensorless management eliminates the necessity for a motor encoder (or resolver) by using a mannequin of the motor traits with present and voltage as suggestions to supply closed-loop efficiency and has a number of advantages.  

Lowered price, elevated reliability – Eliminating the motor encoder and cable reduces system prices and eliminates a possible level of failure. It will increase system reliability towards elements to which an encoder could also be prone, resembling electrical noise, vibration, or temperature

Elevated effectivity – Sensorless management is field-oriented or vector management which optimizes output voltage, subsequently growing energy effectivity primarily based on the precise working load circumstances.

Elevated efficiency – KEB’s sensorless management algorithms are best-in-class, offering a extremely dynamic velocity management response and correct torque management. This leads to quick turn-on occasions for power-on-demand tools recovering from energy-saving standby operation. It will increase efficiency and productiveness with tight regulation in response to load steps and quicker working cycle occasions. It additionally will increase fault safety by mitigating present overshoot and has programmable present limits.   

Lastly, characterizing a motor for sensorless operation is straightforward with the T6 Auxiliary Inverter. The characterization algorithms are strong and suitable with practically all AC motors, whatever the producer (this can be a regularly requested query from first-time customers who’ve struggled with this on different merchandise). KEB’s free Combivis program has easy-to-use setup wizards that stroll the person via the fundamental motor nameplate knowledge (e.g. present, voltage, velocity, frequency, energy) entry. The characterization itself is an automatic be taught course of that solely takes a couple of minutes. When the traits have been acquired, the settings may be saved to shortly fee subsequent motors.  

System Administration and CAN Communications

For system management and diagnostics with the automobile ECU, the T6 Auxiliary Inverter makes use of an embedded controller which acts as a CAN J1939 communications hub and gateway.  

Every auxiliary motor management stage can have configurable transmit and obtain course of knowledge telegrams and SPN mappings in addition to configurable PGN addresses. The advantage of this association is that there’s one 2-wire CAN connection and one Controller ID for controlling and managing a number of auxiliary nodes. This permits the person to find out what knowledge they need to be communicated over the CAN bus for every inverter node and tips on how to prepare the task and addressing. Alternatively, there may be the choice to make the most of pre-installed embedded management packages with pre-configured communication and inverter settings (e.g. Torque/Velocity Management) for fast setup of any node(s). 

Startup Instruments and Help

KEB is thought for its dependable merchandise and buyer assist.  

KEB’s free Combivis program is a robust device to help in startup and adjustment with easy-to-use wizards, helpful diagnostics and troubleshooting options resembling a digital oscilloscope, and TeamViewer is built-in for distant assist. This system can save venture recordsdata and parameter lists for fast setup of subsequent techniques (these recordsdata will also be used to pre-configure the T6 system from the manufacturing unit). 

One other key characteristic is the automated motor be taught wizard. It’s used to characterize motors for sensorless operation. Solely fundamental motor nameplate knowledge is mostly wanted, and the automated course of takes 3 – 5 minutes.  

Along with software program instruments, KEB has devoted eMobility groups for native assist. These groups are regionally primarily based in North America and Europe.  KEB helps at each stage of the venture – design idea, system sizing and choice, startup and commissioning (together with onsite assist, as permitted), collection manufacturing preparation, and technical and after-sales troubleshooting and assist.

If there are auxiliary electrification functions you’d like to debate, please attain out to us at gross sales@kebamerica.com.

Sponsored by KEB


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September 2022