Controller for E-Motor and Electric Powertrain Dynos

ACS provides dynamometer test stand or test cell control with a customizable hardware and software system that is built on the open-source ACS Framework. The primary elements of this system include:

  • Software and control
  • Data acquisition
  • Data display
  • Graphical User Interface (GUI)
  • Manual control
  • Automated test sequencing
  • Data storage
  • Alarming
  • Model based control (optional)

Controller Functionality

The controller provides the following dynamometer control functionality:

  • Steady state and transient motoring/absorbing control modes for torque and speed
  • Use cases that include maintaining steady state speed during load torque transient adjustments and varying speed and torque in parallel over a time sequence

Dyno Control System Features and Options

ACS dynamometer controllers are customized based on system, safety, and user-measurement requirements.

  • NI™ real-time PXIe controller and chassis coupled with customizable IO configurations
  • Controller enclosed in a configurable 19” rack-style enclosure that houses the user interface PC
  • System monitors can be affixed to the rack or provided with an optional worksurface
  • Connectorized panel or interface box can be provided if the control area is not adjacent to the test unit
  • Optional communication modules for interfacing with third-party controllers and devices over Ethernet I/P, EtherCAT, CAN, ProfiNET, Modbus, etc.
  • ACS Framework
    • Modular, flexible platform for real-time test applications
    • Based on LabVIEW software
    • Includes predefined modules including:
      • multi-threaded profile execution
      • data logging
      • calculations
      • alarm monitoring
    • Functions can be customized as required:
      • Real-time control and data acquisition
      • Monitor and display test stand signals
    • Executes automated test sequences
    • Provides manual control and diagnostics

All of ACS’ LabVIEW software development meets or exceeds recommended best practices as defined by NI™. Code developed by ACS is architected and reviewed by Certified LabVIEW Architects (CLA).

Customized Graphical User Interface (GUI)

controller e motor dynos, controller electric powertrain dynos

  • GUI represents the data that needs to be displayed for operators and staff during test operations
  • Manual control capability as applicable for the test system’s current state
  • User can access the included test creation, editing, and report tools
  • Configured to monitor all subsystem safeties, alarms, and emergency stop either through bus communication or discrete IO points via the included safety module or other inputs
  • Key, main system sensors are monitored for operation outside of limits
  • Limits and limit actions are adjustable by a “super user”

PLC-based safety and emergency stop

  • Computer-independent system monitors and automatically shuts the system down to prevent personnel or property damage.
  • Test stand includes sensors that are tied into this system, and it can be configured to have additional inputs and/or sensors that can be placed in series to expand and allow the user to incorporate safeties outside of the test stand, for example in the test bay, control room, or other facility or UUT (Unit Under Test) inputs.
  • Safety system events are displayed and annunciated on the GUI.