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ES5340.2 Electric Drive Simulation Board - User’s Guide

ETAS

Introduction

The following figure shows the front panel of the ES5340.2 Electric Drive Simu-
lation Board with the various connections.

Fig. 1-3

Front panel of the ES5340.2 Electric Drive Simulation Board
(left: master, right: slave)

The function and assignment of the connectors are described in Chapter "Con-
nector Assignment and Display Elements" on page 97.

Summary of Contents for ES5340.2

Page 1: ...ES5340 2 Electric Drive Simulation Board User s Guide...

Page 2: ...ment or single license Using and copying is only allowed in concurrence with the specifications stipulated in the contract Under no circumstances may any part of this document be copied reproduced tra...

Page 3: ...am 12 1 4 Basic Safety Instructions 13 1 4 1 Labeling of Safety Instructions 13 1 4 2 General Safety Information 13 1 4 3 Requirements for Users and Duties for Operators 13 1 4 4 Intended Use 14 1 5 I...

Page 4: ...n 42 3 6 2 Configuring the Digital Inputs 43 3 6 3 Configuration with ES5436 1 to Measure ECU Digital Output Signals 44 3 6 4 Configuration as H Bridge 46 3 7 RPM Generator 47 3 7 1 Angle Clock Signal...

Page 5: ...ments 97 6 1 Connector Assignment 98 6 1 1 Connectors for the Outputs ES5340 2 M and ES5340 1 S 98 6 1 2 Connectors for the Inputs ES5340 2 M only 99 6 1 3 Connectors for the Angle Clock Signal ES5340...

Page 6: ...ES5340 2 Electric Drive Simulation Board User s Guide 6 Contents ETAS...

Page 7: ...as resolvers sine and digital encoders can be displayed Other analog and digital signals are also possible such as fault signals battery charge levels or DC DC converter control 1 1 2 Inverter PMSM1 M...

Page 8: ...to be simulated Parameterization of the PMSM The PMSM is likewise configured via typical variables such as the number of pole pairs and cogging positions Additional variables such as resistance induc...

Page 9: ...easurement of the PWM control signals for the inverter RPM Unit The RPM unit present on the ES5340 2 can take over the position and speed of the electric motor calculated by the model and then functio...

Page 10: ...1 S on page 10 1 2 1 Electric Drive Simulation Master Board ES5340 2 M This board contains the full range of function I O 8 analog outputs incl simulation of analog position sensor signals 8 digital o...

Page 11: ...front panel of the ES5340 2 Electric Drive Simu lation Board with the various connections Fig 1 3 Front panel of the ES5340 2 Electric Drive Simulation Board left master right slave The function and a...

Page 12: ...n Analog Output Multiplexer Digital Value 1 6 Open Collector Output CH0 CH5 Galvanic Isolation Digital Output Multiplexer DSUB25 Analog Input Measurement Digital Input Measurement RPM Generator Analog...

Page 13: ...r damage which is caused by incorrect use and handling and not adhering to the safety instructions 1 4 3 Requirements for Users and Duties for Operators The product may be assembled operated and maint...

Page 14: ...lowing Use within a vehicle on the road Use as part of a life support system Use as part of a medical application Applications in which misuse may result in injury or damage Use in environments in whi...

Page 15: ...0 The lab power supply must be approved for use at a height of 2000 m and in ambient temperatures of up to 40 C De Energizing a Plug In Board Switch off the ES5300 1 A Housing or the ES5300 1 B Housin...

Page 16: ...t WARNING This is class A equipment This equipment can cause radio interfer ence in residential areas Should that be the case the operator may be requested to institute reasonable measures CAUTION The...

Page 17: ...Board User s Guide 17 ETAS Introduction Maintenance The product does not require maintenance Repairs If an ETAS hardware product needs to be repaired return the product to ETAS Cleaning The product i...

Page 18: ...e Republic of Korea 1 5 3 RoHS Conformity European Union The EU Directive RoHS 2011 65 EU limits the use of certain dangerous materials for electrical and electronic devices RoHS conformity ETAS confi...

Page 19: ...t be disposed of as residual garbage The user is obliged to collect the old devices separately and return them to the WEEE take back system for recycling The WEEE Directive concerns all ETAS devices b...

Page 20: ...l activities to be carried out by the user are shown in what we call a Use Case format i e the target to be achieved is defined briefly in the title and the individual steps necessary to achieve this...

Page 21: ...blue Press ENTER Keyboard commands are shown in angled brackets in block capitals The Open File dialog box appears Names of program windows dialog boxes fields etc are shown in quotation marks Select...

Page 22: ...ES5340 2 Electric Drive Simulation Board User s Guide 22 Introduction ETAS...

Page 23: ...he tips and instructions contained in this chapter Master Slave Configuration on page 25 To extend the I O capacity of the ES5340 2 M master a slave card ES5340 1 S can be installed This makes it poss...

Page 24: ...rve the following when installing an ES5340 2 Electric Drive Simula tion Board Before installation power off your Real Time PC and disconnect it from the mains Please take the following precautionary...

Page 25: ...ressed by the FPGA model with the typically low latencies 1 s see Connecting Master and Slave via Gigabit Link on page 25 Using a Model on the Real Time PC In this case the ES5340 1 S can simply be in...

Page 26: ...en act as RPM master in the system For this purpose the RPM buses of the master and of one or more of the slaves have to be connected as described below 2 3 1 Connecting the RPM Buses of Two Boards Th...

Page 27: ...Fig 2 1 Connecting the RPM buses of two boards 2 3 2 Configuration of the RPM Unit in LABCAR RTC The allocation of whether an RPM unit is to act as a master or slave is defined in the relevant ES5340...

Page 28: ...re Exclusive Core Usage This means that between the control signals being output and the current signals being measured there are no raster losses in the ECU Prerequisites To use this mode the process...

Page 29: ...iguration in LABCAR RTC 2 Select the item ES5340 Dig In Inverter Meas 3 In the Globals tab select the required settings for the options Trigger Mode and Nominal PWM Period Time of Center Aligned PWM s...

Page 30: ...ive Simulation Board User s Guide 30 Installation and Configuration ETAS 7 Select the required task and click Ok 8 Set the polarity of the gate signals in the Signals tab Center Logic column 9 Save th...

Page 31: ...sed for different digital signals via an output multi plexer Specification on page 38 Configuring the Digital Signals on page 40 Output Multiplexers for the Digital Signals on page 41 Each digital out...

Page 32: ...c strength of 60 V In addition each output has a cutoff relay The accuracy internal reference is 5 mV while the maximum current of an output is 30 mA The following illustration shows the schematic cir...

Page 33: ...nels themselves as follows Analog Direct Out This can be used to output constant voltages and values calculated in the com putation grid of an RTPC model specified by the value of OutValue_n 1 0 to 1...

Page 34: ...log chan nels can be used for the A and B signals see Fig 3 4 Fig 3 4 Signals A and B of the sine encoder Note When using a resolver as position sensor AGND of channel 6 pin 43 and 44 of the DSUB62HD...

Page 35: ...that the output signals are not step functions with the step size of the PC based model but rather are output continuously so to speak The signal generators are controlled by the central RPM unit whic...

Page 36: ...iven by two different sources Outputs of the FPGA model Signals of type Analog Direct Out and analog arbitrary signals incl position sensors such as resolvers and sine encoders The sources are configu...

Page 37: ...r Voltage through low side switch phase X I_element_XH X U V W Inverter Current through the high side switch phase X I_element_XL X U V W Inverter Current through the low side switch phase X I_DC Inve...

Page 38: ...S5340 2 M has eight digital outputs while the ES5340 1 S has six dig ital outputs 3 3 1 Specification The output voltage is 0 to 60 V open collector or 5 V internal pull up All outputs are galvanicall...

Page 39: ...3 is closed Generation of a digital output signal Digital Output i The signal that is set in the Signals tab through Output Select deter mines the cycle time for S2 The pull up resistor determines the...

Page 40: ...rop off of the edges see Fig 3 7 Fig 3 7 Timing for 120 phase shifted pulses with 180 duration Digital Direct Out These outputs enable you to directly stimulate ECU inputs using values from the model...

Page 41: ...t SENT V3 The delayed control signals for the inverter six inverter control signals with an adjustable time delay can be output to the ECU for diagnostic purposes The sources are configured in LABCAR...

Page 42: ...y voltages and other constant voltages control signals The type of averaging used for the detected signals can be configured in LAB CAR RTC in the ES5340 Analog In item of the Globals tab 3 6 Digital...

Page 43: ...340 Dig In HW For configuring the measurement of inverter gate signals ES5340 Dig In Inverter Meas If a model is run on the Real Time PC an item must be added for measure ment of the inverter gate sig...

Page 44: ...of the ES5340 Technical Data of the ES5436 1 Power Sources Tab 3 1 Technical data of the power sources When connecting the ES5436 1 observe the following note CAUTION Before connecting the ES5436 1 r...

Page 45: ...436 1 as load simulation ES5340 VBAT Input_n ES5436 VBAT Chan_x VBAT_x X1 VBAT VBAT_x ECU VBAT ECU with Open Emitter Pull Down Configuration VBAT VBAT ECU VBAT ECU with Open Collector ES5436 Chan_x VB...

Page 46: ...sed for an H bridge Only if channels 2i and 2i 1 are used there will be a current flow through the H bridge Note The ES5436 1 use cases Pull Up Pull Down and Bipolar for H bridge can be configured by...

Page 47: ...tion signal at 0 CA The actual clock signal The signal for the direction of rotation DOR A High level of the DOR signal means Rotation with increasing crank shaft angle while a Low level means Rotatio...

Page 48: ...unit is then sped up or slowed down this ensures that the speed difference is eliminated within the next sim ulation period without changing the number of pulses of a mechanical period 360 Configurin...

Page 49: ...ery accurate calculation of the simulated phase currents Within the entire model calculation takes place using floating point arithmetic rather than fixed point arithmetic As a result a very high leve...

Page 50: ...rn calculating the switching phases of the switches in the inverter branches Fig 4 2 Measurement and control variables of the inverter ECU Synchronous Motor PMSM The PMSM part of the model is used to...

Page 51: ...following properties Switches can be high or low active Simulation of hardware failures switches always open or closed Simulation of phase voltages U_Phase_X X U V W and U_d U_q Simulation of phase v...

Page 52: ...rough when gate is High Low Active switches through when gate is Low High Active R_SW_ON Resistance of the switch in conductive state 20 C 68 F 0 001 U_SW_Fwd V Forward voltage across switch in conduc...

Page 53: ...ts of the inverter model to other models in the Con nection Manager of LABCAR IP or stimulate them in the Signal Center in LABCAR EE Tab 4 2 Inputs of the inverter model Input unit Description Default...

Page 54: ...UX I_DC A Total inverter current Analog MUX U_DC V Inverter voltage Analog MUX I_element_XH X U V W A Current through upper switch phase X Analog MUX I_element_XL X U V W A Current through lower switc...

Page 55: ...se_V for the matching of position sensors Simulation of ohmic losses Setting of simulation start values for I_d and I_q R_d R_q L_d L_q and magnetic flux can be changed in real time Parameters The par...

Page 56: ...Input unit Description Default value Rd Coil resistance in d direction 0 0125 Rq Coil resistance in q direction 0 0125 Ld H Coil inductance in d direction 0 000211 Lq H Coil inductance in q direction...

Page 57: ...the FPGA model Tab 4 7 Parameters of the mechanical model Inputs You can connect the inputs of the mechanical model to other models in the Connection Manager of LABCAR IP or stimulate them in the Sign...

Page 58: ...o other models in the Connection Manager of LABCAR IP Tab 4 9 Outputs of the mechanical model Output unit Description Signal available as multiplexer input Omega_mech 1 s Angular velocity rotor Analog...

Page 59: ...makes it possible to detect a PWM signal via Hard ware with a high accuracy and directly use this signal in the inverter model The model consists of three parts Inverter Induction machine IM Mechanica...

Page 60: ...load torsional stiffness and damping The load torque of the drive train can be changed by the user during runtime 4 2 1 Inverter Parameters Inputs and Outputs Parameters Tab 4 10 Parameters of the inv...

Page 61: ...ve state 20 C 68 F 0 0 0 05 0 001 R_D_Fwd Resistance of the diode in conductive state 20 C 68 F 0 0 0 05 0 001 Output unit Model Value min default range Model Value max default range DAC Voltage min d...

Page 62: ...U V W A Initial current in stator phases 1500 1500 0 I_rotor_X_Init X U V W A Initial current in rotor phases 1500 1500 0 a_M 1 K Temperature coefficient of ohmic resistance of the stator coils 0 0 0...

Page 63: ...0 10 0 10 0 10 0 U_ind_X X U V W V 1500 1500 10 0 10 0 10 0 10 0 T_el Nm 1000 1000 1000 1000 1000 1000 10 0 10 0 10 0 10 0 P_loss_M W 4000 0 0 20000 4000 0 0 20000 Parameter unit Descriptions Value r...

Page 64: ...value max default range DAC voltage min default min DAC voltage max default max Omega_mech rad s 50000 50000 50000 50000 50000 50000 10 0 10 0 10 0 10 0 Phi_mech 0 0 360 360 0 360 0 10 0 10 0 10 0 Om...

Page 65: ...Measuring the Gate Trigger Signals on page 67 RPM Unit on page 69 Integration of the Model on page 71 The next step consists of configuring the connections to a model FPGA model on page 71 Software Mo...

Page 66: ...n page 66 Adding an ES5340 Digital In Item on page 67 Adding an ES5340 Dig In HW Item on page 67 Assigning Inverter Gates to Measurement Channels on page 68 Creating an ES5340 RPM Item on page 69 5 1...

Page 67: ...ol signals for the inverter you have to add an item for measuring digital signals Adding an ES5340 Digital In Item 1 Right click the ES5340 Master item and select Add Item 2 In the list select the ES5...

Page 68: ...added Assigning Inverter Gates to Measurement Channels For the ES5340 2 M we assume that six gate signals are present two for each phase 1 Assign the gate signals to the desired measurement channels...

Page 69: ...ng threshold val ues accordingly 5 1 3 RPM Unit The RPM unit is used to generate speed and angle information that is required by position sensors and other angle synchronous signals Creating an ES5340...

Page 70: ...oard User s Guide 70 Configuring the Hardware in LABCAR RTC ETAS 3 For the specific application Electric Motor con figure the settings in the Globals tab as shown The ES5340 2 can thus be configured a...

Page 71: ...el on page 71 Adding the FPGA Model in LABCAR RTC on page 71 Configuring the Model Parameters on page 73 Configuring the Value Ranges on page 74 Determining Default Values on page 75 Configuring Outpu...

Page 72: ...ES5340 2 Electric Drive Simulation Board User s Guide 72 Configuring the Hardware in LABCAR RTC ETAS 2 From the list select the ES5340 PMSM X X X item and click OK The item is added...

Page 73: ...he Hardware in LABCAR RTC Configuring the Model Parameters The model is configured in the Globals tab and is divided into three model components Inverter PMSM and Mechanics Note For a detailed descrip...

Page 74: ...alid value ranges for the model variables are configured in the Signals tab Adapt the mapping between the physical and electrical variables according to your hardware Note Note that the values of DAC...

Page 75: ...gnals from the ECU in addition a map of the current voltage values to the analog outputs must be created The duty cycles and the period of the PWM control signals are measured and forwarded to the sof...

Page 76: ...length of the PWM task of the ECU 5 In the Groups tab select the task to be activated in the Real Time PC after each period of the PWM measurement Note If you enter 0 0 here the period of the Receive...

Page 77: ...exist Direct output The values of the model are converted from physical to electrical values and enabled on the D A converter on the ES5340 2 Predicted output Only the amplitude and phase of the AC s...

Page 78: ...desired outputs For an additional configuration of this item refer to the section on Analog Out puts on page 84 Adding Analog Outputs for Predicted Values 1 Insert an ES5340 Analog Out item as describ...

Page 79: ...9 ETAS Configuring the Hardware in LABCAR RTC 5 So that the phases of the signals can still be changed later for the option Clock Source select the setting Phase Shifted Mech Angle 6 To enable synchro...

Page 80: ...ES5340 2 Electric Drive Simulation Board User s Guide 80 Configuring the Hardware in LABCAR RTC ETAS 7 Finally you can configure default values for the amplitude and phase in the Data tab...

Page 81: ...l sources of the analog multiplexer on page 92 Configuring the voltage reference and output type on page 93 Defining the Default Values on page 94 Configuring the Signal Sources of the Digital Multipl...

Page 82: ...t age reference and output type on page 93 The type Sine Encoder does not need an exci tation signal and has a single ended output 4 Define the number of pole pairs 5 For SYNC Clock Source select the...

Page 83: ...uide 83 ETAS Configuring the Hardware in LABCAR RTC 3 As the operating mode select Digital Position Sensor 4 Define the number of pole pairs 5 For SYNC Clock Source select the setting Direct Mech Angl...

Page 84: ...hese outputs are used to output analog values from a model to the A D con verters of the ECU Adding Outputs of Type Direct Analog Out 1 Right click the ES5340 Master item and select Add Item 2 In the...

Page 85: ...Adding Outputs of Type Analog Arbitrary Outputs for arbitrary signals can be used to output user defined signal patterns based on the current angle of the simulated electric motor This signal pattern...

Page 86: ...fted angle e g for predicting current values can be used 5 With the WaveformTable option you can edit the desired output in the form of a table 6 Select the Data tab to configure default values for th...

Page 87: ...rdware in LABCAR RTC 3 Leave the option Use Mode for Digital Output Device in the default setting Digital Direct Out 4 To configure multiple digital outputs in this item select the desired number in t...

Page 88: ...ased on the current angle of the simulated electric motor This signal pattern can be used for example to simulate specific position sensors and other variables with a direct relationship to the motor...

Page 89: ...ent values can be used 5 With the WaveformTable option you can edit the desired output in the form of a table 6 Select the Data tab to configure default values for the outputs 5 3 4 Analog Inputs The...

Page 90: ...ate an average of a configurable number of measured values 5 3 5 Digital Inputs The digital inputs can be used to measure various properties of digital signals frequencies duty cycles etc Adding a Dig...

Page 91: ...ethod in the Measurement Procedure column For a digital input channel multiple measurements can be car ried out For each ES5340 Dig In Meas item ten measure ments are possible if more measurements are...

Page 92: ...tem and select Add Item 2 In the list select the ES5340 Analog Out Mux item and click OK The item is added 3 Switch to the Signals tab In the Output Select column you can now define a signal source fo...

Page 93: ...t type 1 In the Reference Voltage column select whether the internal reference voltage or an external refer ence voltage is to be used 2 In the Output Mode column select whether the signal is to be co...

Page 94: ...r a digital output multiplexer Configuring the Signal Sources of the Digital Multiplexer 1 Right click the ES5340 Master item and select Add Item 2 In the list select the ES5340 Digital Out Mux item a...

Page 95: ...Direct digital output Digital Direct Out Digital arbitrary signals Digital Arbitrary Feedback of the inverter gate signals The PWM signals can be fed back for diagnostic purposes with a configurable...

Page 96: ...e Data tab to configure default values for the outputs 2 Four different settings exist for the output control Exiting LABCAR RTC 1 Save the settings with File Save 2 In LABCAR IP start the code genera...

Page 97: ...2 Electric Drive Simulation Board It consists of the following sec tions Connector Assignment on page 98 Here all connectors on the front panel are described Connectors for the Outputs ES5340 2 M and...

Page 98: ...al Pin Signal 1 Analog Output Channel 0 14 Ground Channel 0 2 External Ref Channel 0 15 Digital Output Channel 0 3 Analog Output Channel 1 16 Ground Channel 1 4 External Ref Channel 1 17 Digital Outpu...

Page 99: ...s Guide 99 ETAS Connector Assignment and Display Elements 6 1 2 Connectors for the Inputs ES5340 2 M only The connector is a DSUB62HD connector male The shielding is to protective earth Fig 6 2 Connec...

Page 100: ...Ground 9 Digital Input Channel 4 30 Digital Input Channel 17 51 Digital Input Ground 10 Digital Input Channel 5 31 Digital Input Channel 18 52 Digital Input Ground 11 Digital Input Channel 6 32 Digit...

Page 101: ...panel of the ES5340 2 Electric Drive Simulation Board has an LED for identifying the board from the Web Interface of LABCAR RTPC Note If using a resolver as position sensor AGND of channel 6 has to be...

Page 102: ...ES5340 2 Electric Drive Simulation Board User s Guide 102 Connector Assignment and Display Elements ETAS...

Page 103: ...Electric Drive Master Board Multi I O ES5340 2 M F 00K 107 937 Optional Accessories Electric Drive Slave Board Multi I O ES5340 1 S F 00K 107 054 FPGA Inverter PMSM Model for ES5340 LCM_PMSM5340 F 00...

Page 104: ...the repair order on the ETAS homep age Navigating to the repair page 1 Go the ETAS website www etas com 2 Click Support Center Hardware Return Repair Form The page is opened Entering contact informat...

Page 105: ...On the Required Hardware Service page select the option Upgrade please attach an offer as the reason for the return 2 In the field Your Purchase Order Number for the repair enter the order number of t...

Page 106: ...voice address 1 Enter the Invoice Address on the corresponding page This should match the address on your quote offer Selecting the delivery type 1 On the Delivery Instructions page select the option...

Page 107: ...Product Informa tion page Product Name ES5340 2 M ETAS Part Number F 00K 107 937 The serial number of your ES5340 2 M 3 In the Failure Description field enter a text such as Upgrade for ES5340 with LC...

Page 108: ...Guide 108 Order Information and Scope of Delivery ETAS Summary of the repair order 1 The last page shows a summary of the order 2 Review the data once again 3 If necessary select a link at the bottom...

Page 109: ...nd Scope of Delivery 4 Then print out the form sign it and send it along with the hardware and the quote to the ETAS Repair Department specifying the RMA number Upon successful completion of the RMA o...

Page 110: ...ES5340 2 Electric Drive Simulation Board User s Guide 110 Order Information and Scope of Delivery ETAS...

Page 111: ...16 bit Overvoltage protection 60 V Galvanic isolation Yes Number on ES5340 2 M 8 Number on ES5340 1 S 6 Output voltage range Open collector 0 to 60 V Internal pull up 5 V Output current Max 15 mA Freq...

Page 112: ...of 400 W Number 4 Input voltage range 0 5 V CH0 CH2 0 V to 40 V CH1 CH3 Accuracy 50 mV CH0 CH2 200 mV CH1 CH3 Resolution 12 bit Impedance 1 M Sampling rate 500 kSamples s Overvoltage protection 60 V...

Page 113: ...t Use only inside enclosed and dry rooms Max contamination level 2 Temperature during operation 5 C to 40 C 41 F to 104 F Relative humidity 0 to 95 non condensing Operating altitude Max 2000 m above s...

Page 114: ...ngs in accordance with EN 61326 1 Avoid potential radio interference when using the module outside of the industrial settings with additional shielding measures WARNING This is class A equipment This...

Page 115: ...nical Support For details of your local sales office as well as your local technical support team and product hotlines take a look at the ETAS website Borsigstra e 24 Phone 49 711 3423 0 70469 Stuttga...

Page 116: ...ES5340 2 Electric Drive Simulation Board User s Guide 116 ETAS Contact Addresses ETAS...

Page 117: ...A and B of the sine encoder 34 Fig 3 5 FPGA model signals as inputs for the analog multiplexer 37 Fig 3 6 Schematic circuit diagram of a digital output 39 Fig 3 7 Timing for 120 phase shifted pulses...

Page 118: ...ES5340 2 Electric Drive Simulation Board User s Guide 118 Figures ETAS...

Page 119: ...18 Cleaning 17 Connecting Disconnecting Devices 16 Connector angle clock signal 101 input signals 99 output signals 98 Connectors 97 D De Energizing a Plug In Board 15 Digital Arbitrary 40 Digital Di...

Page 120: ...urces 36 41 P PMSM model 49 inverter 51 mechanical system 57 synchronous machine 55 Product Back 19 Product non liability 13 Properties 7 R REACH 19 Recycling 19 Repairs 17 Requirements for Operation...

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