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The Motor Control Unit (MCU) is the core electronic control component of the drive system in new energy vehicles. It is responsible for converting high-voltage DC power into high-voltage AC power to drive the motor, thereby enabling the vehicle to operate. Due to its critical role in vehicle operation, the safety and reliability of the MCU are paramount. Therefore, it must undergo rigorous testing and validation, including functional testing, durability testing, overload protection testing, and environmental adaptability testing, to ensure the MCU's stability and safety under various operating conditions. This effectively prevents potential faults, enhancing the overall safety and reliability of the vehicle and ensuring the user’s driving experience and the vehicle’s long-term operation.

VCARSYSTEM's Solution

VCARSYSTEM's Motor Power Simulation System provides a development and testing environment for the power stage of Permanent Magnet Synchronous Motor (PMSM) controllers, designed to simulate the operating characteristics of real PMSMs and their electronic control systems. The system integrates motor-in-the-loop simulation testing interfaces, including power simulation, position sensor simulation, fault injection simulation, and digital/analog IO input/output interfaces, to meet diverse testing needs. Users can easily configure motor parameters to simulate the UVW output characteristics under different parameters, allowing for efficient testing of the electronic control system's performance in various scenarios.

HIL SYSTEM

VCARSYSTEM offers Hardware-in-the-Loop (HIL) testing solutions that cover the entire scope of automotive electronics, including modules for new energy powertrain systems (BMS/VCU/MCU), automotive driving systems (ACC/LKA/AEB, etc.), chassis electronic control systems (EPS/ESP/SBW/EPB/EHB/EMB), traditional powertrain systems (EMS/TCU), as well as body electronics and intelligent cockpits. It provides comprehensive HIL testing services to help customers accelerate product launch timelines.

VCAR EM

VCAR EM, developed by VCARSYSTEM for HIL platforms, is an engineering configuration tool that enables comprehensive HIL project setup. The software facilitates GPIO signal configuration, bus communication configuration for CAN/CAN FD, LIN, Ethernet, board hardware configuration, simulation model import, signal mapping, real-time host multi-task allocation and management, and project compilation. It also supports multi-task distribution management and multi-device daisy-chaining configuration, meeting diverse testing scenario requirements.

FUNCTIONS

Motor Power Consumption and Operating Condition Simulation

Simulates the real power consumption of the motor, accurately reproducing its operating characteristics. Through power factor correction (PFC) and a boost source (boostSrc), it simulates reverse charging, replicating power scenarios in real-world applications.

Electrical Parameter Collection and Signal Interaction

Real-time collection and processing of data such as voltage, current, and induced electromotive force (EMF) for precise monitoring. Receives CANFD (Controller Area Network Flexible Data Rate) model signals, tracks the electrical angle, and generates real-time variations of the induced electromotive force.

Signal Synchronization and Multi-Board Coordination

Ensures the synchronization and calibration accuracy of the three-phase signals, guaranteeing the system’s performance precision. Manages power distribution and synchronization across multiple power boards, enabling seamless operation.

Comprehensive Circuit Protection and Fault Handling

Provides quadruple protection against overvoltage, overcurrent, overtemperature, and undervoltage, while also offering fault handling and status reporting capabilities.

Current Signal Acquisition and Vector Analysis

Captures real current signals of Ia, Ib, and Ic with 16-bit analog-to-digital converter (ADC) accuracy, and calculates the Id and Iq spatial vectors, providing support for detailed analysis.

Motor Core Parameter Calculation

Calculates the motor torque based on parameters such as magnetic flux and pole pair number. Combines rotational inertia and load to calculate motor speed ω, electrical angle θ, and acceleration, enabling precise modeling.

Signal Transmission and Generation

Transmits model parameters at a refresh rate of 10k times per second via CANFD to meet high-speed communication requirements. Generates digital signals for rotary transformers, hall sensors, optical encoders, etc., adapting to a variety of application scenarios.

Multi-Model Control and Internal Signal Simulation

Can simultaneously control multiple motor models for comprehensive testing and simulation. Simulates other internal signal outputs, providing support for diverse system requirements.

ASSOCIATED PRODUCTS

HIL SYSTEM

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VCAR EA

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VCAR EM

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