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Inverter test bed

An inverter test bed is used to test and measure inverters under defined and reproducible conditions. The inverter converts the direct current supplied by a battery or rechargeable battery into a defined alternating current, for example to supply an electric drive. This energy conversion process can also take place in the opposite direction, for example when feeding electrical energy back into the grid from PV systems or during electrical braking, known as recuperation.

The major advantage of an inverter test bed is that electrical and thermal loads as well as realistic operating conditions can be simulated in a controlled manner in the laboratory. This can be done at an early stage of development, before the electric motor or battery is available, which is an advantage in overall vehicle development and reduces costs. In contrast to measurements in the vehicle or in field tests, environmental conditions, load profiles, voltages, currents and temperatures can be precisely controlled and repeated at any time on the testbed.

The test bed can be conditioned in terms of ambient temperature, humidity and cooling circuit conditions, enabling even extreme operating conditions to be reliably simulated. Furthermore, different motor types and power ratings can be tested variably without having to connect the inverter to different motors. Different charge states can be tested dynamically, as can different battery supply voltages.

Photo: (c) AVL SET GmbH

The test bed can be used for the following tasks:
  • Characterisation, functional and performance tests of inverters
    • for HEV, PHEV and BEV as well as HV charging systems
    • Motor types: PMSM, ASM, EESM and SRM
    • Testing up to performance limits and misuse tests
    • under defined climatic conditions
  • Accredited efficiency measurement
  • Loss analyses and loss characteristic curves
  • Characterisation of the inverter under different load and frequency conditions
  • Thermal investigations and cooling performance evaluation
  • Endurance tests and service life investigations
  • Functional and safety tests (e.g. protective functions, shutdown behaviour, insulation monitors)
  • Validation of different control strategies

The main purpose is to verify and qualify inverters in accordance with technical requirements, specifications and standards as required for development, homologation and series approval. In addition, accompanying development measurements are carried out on the testbed, for example to optimise efficiency or control algorithms.

The measurement results include voltage, power and current curves, switching losses, overall efficiency, temperature profiles and thermal behaviour under dynamic load conditions. Various electrical operating points, load cycles or driving profiles can be simulated, as they occur in real electric drives.

The great advantage of the FH JOANNEUM test bed is that the inverters can also be tested in combination with real motors, as a powertrain test bench with a battery emulator is also available. This combination allows further developments to be made to both the inverter and the motor in a targeted and rapid manner.

Service description
  • Accredited measurements are sought
  • Recording of efficiency and loss characteristic curves
  • Performance tests
  • The following motors can be simulated:
    • PMSM
    • ASM
    • EESM
    • SRM
  • Tests up to the performance limit of the inverter or system
    • DC: 1200 V / 1200 A (30 s) / 800 A (cont.)
    • AC: 1200 Vpeak / 800 Arms
  • Misuse test and fault tests
  • Short-circuit tests
  • Phase failure tests
  • Air conditioning from 10°C to 95°C / 10% – 98% RH
  • Temperature range -70°C to 180°C
  • Cooling water -40°C to 140°C (water/glycol: 40/60)
Features
  • Manufacturer: AVL List
  • Automation system: PUMA
  • Year of purchase: 2026 (currently under construction)
  • Measuring system: X-ION
  • Residual bus simulation
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