Enhancing Performance and Dependability in E-Drive Testing: A Comprehensive Approach for Communication Reliability and Test Bench Operation Safety

Given the escalating demand for electric vehicles, E-drive test benches have become instrumental in pre-production testing of motors and inverters. The test bench's communication system comprises the exchange of data between the inverter and Controller unit over the Controller Area Network (CAN) bus. However, the presence of a high electromagnetic environment during rigorous testing poses a risk of data corruption, potentially leading to fatal consequences. Any communication system error causing data corruption can impact the quality and dependability of the test results. This paper proposes a methodology to implement a communication error detection system in the test bench, similar to the one used in actual vehicles. The objective is to ensure real-time detection of communication errors and ensure the accuracy and reliability of the test results. Additionally, the proposed methodology offers cost savings by eliminating the need for additional vehicle network toolboxes and reducing expenses associated with real-time controller software. By avoiding the requirement for extra hardware or software components, the overall implementation costs are significantly reduced. The results of this study demonstrate that the proposed method effectively detects communication errors, thereby enhancing the overall efficiency and cost-effectiveness of the E-drive test bench setup. This research paper also addresses the challenges associated with the operation of an E-Drive test bench, specifically focusing on the independent operation of the Dyno motor and Battery simulator. These components pose risks of voltage spikes and potential damage to the test bench. To mitigate these risks, a control system is implemented to monitor and regulate the components, ensuring the prevention of harmful voltage spikes and safeguarding the integrity of the test bench. The proposed safety model and control system enhance the reliability and safety of the E-Drive test bench, contributing to the overall functionality and performance of the system.