EV Drive Line Simulator with Controller Development & Validation Platform

The EV Driveline Simulator with Controller Development & Validation Platform is a modular, hands-on system that replicates the full “grid-to-wheels” ecosystem of an electric vehicle. It features a 5kW PMSM traction motor coupled with a dynamometer for road-like loading and regenerative braking studies, powered by a lithium-ion battery pack with integrated BMS for SOC/SOH monitoring and safety. At its core is the Motor Controller Development Platform, where users can edit, program, and validate custom control algorithms—from Field-Oriented Control (FOC) to advanced predictive strategies—on real hardware. The setup also includes an onboard charger (OBC), AC charging station (EVSE), and a central data acquisition system for real-time monitoring, drive cycle simulation, and fault diagnostics. Together, it enables comprehensive learning, research, and innovation in electric mobility.

Key Features

Complete EV Driveline Simulation:
Replicates grid-to-wheels energy flow including traction motor, dynamometer, battery, OBC, and charging station.
Modular & Scalable Design:
Subsystems are plug-and-play, supporting flexible configurations for teaching and research.
Traction Motor with Dynamometer:
5kW PMSM with torque sensor and encoder for speed–torque mapping, efficiency curves, and dynamic load response.
Programmable Motor Controller:
Supports Field-Oriented Control (FOC), V/f, and custom algorithms with open software for user-defined strategies.
Battery Integration with BMS:
Lithium-ion traction battery monitored for SOC, SOH, temperature, and regenerative charging performance.
Realistic Charging Infrastructure:
Includes onboard charger (OBC) and EVSE emulator with pilot-signal communication and fault injection scenarios.
Drive Cycle Testing:
Simulates standardized cycles (IDC, NEDC, WLTP) or custom torque/speed profiles to analyze efficiency and range.
Regenerative Braking Studies:
Captures and dissipates recovered energy, enabling analysis of braking torque, SOC impact, and system efficiency.
High-Speed Data Acquisition:
DAQ system records voltage, current, torque, speed, and temperature (>10kHz) with visualization and logging tools.
Built-in Protections:
Overcurrent, overvoltage, short-circuit, and thermal safeguards ensure hardware and user safety.
Custom Algorithm Development:
Open framework for testing novel motor control, predictive, and adaptive algorithms.
Educational & Research Ready:
Ideal for hands-on learning, controller validation, and advanced research in e-mobility systems.

Learning Module

Motor & Controller Development

Characterize motor performance through speed–torque mapping, efficiency curves, and thermal studies.
Implement and tune control strategies such as Field-Oriented Control (FOC), V/f, and four-quadrant operation.
Program and validate custom controller algorithms directly on the inverter hardware.
Analyze system response under dynamic load and regenerative braking conditions.

Drive Cycle, Battery & Charging Studies

Run standardized drive cycles (IDC) and create custom drive cycles.
Study battery performance, SOC/SOH variation, and regenerative energy recovery.
Test onboard charger (OBC) and EVSE protocols including CC, CV, and CC–CV charging.
Evaluate charging efficiency, protocol validation, and fault handling scenarios.

System Performance & Research Applications

Conduct regenerative braking efficiency analysis at varying SOC levels.
Log and visualize high-speed data (>10kHz) for voltage, current, torque, speed, and temperature.
Compare experiments through dashboards and overlays to study efficiency trends.
Extend into advanced research areas such as predictive algorithms, adaptive motor control, and fault diagnostics.

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