Electric Vehicle Industries

An electric vehicle generally contains the following major components: an electric motor, a motor controller, a traction battery, a battery management system, a plug-in charger that can be operated separately from the vehicle, a wiring system, a regenerative braking system, a vehicle body and a frame.
The battery management system is one of the most critical part of Electric or hybrid vehicles. The operating temperature and voltage are the most important parameters that determine the performance. The BMS monitors voltage, current, temp, state of charge, state of power, coolant flow, safety and health.

Case studies

1. BMS – Battery Management System

The implementation of an advanced Battery Management System (BMS) for electric vehicles (EV) has many challenges, ranging from accurate parameter monitoring to efficient control mechanisms. By integrating sophisticated monitoring systems and robust control mechanisms, these challenges can be effectively addressed. The seamless integration of communication protocols ensures reliable data exchange, while adaptive control strategies BMS play an important role in the safety, efficiency, and reliability of electric vehicles, creating the foundation for an electric and sustainable future.

Monitoring Parameters:

  1. Voltage
  2. Temperature
  3. Current
  4. Calculation of Charge/Discharge Limits
  5. State Monitoring: SOC, SOH, and SOF( state of charge, state of health and state of function)

Communication Protocols: Integrating multiple communication protocols poses compatibility and reliability challenges, crucial for seamless data transfer and effective BMS operation.

Control Mechanisms: Implementing effective protection mechanisms and advanced control strategies is critical for battery safety and operational efficiency.

Solution: By deploying high-precision sensors and advanced hardware integration real-time acquisition is achieved.

Using the NI( National Instruments ) and other standard or customized hardware, LabVIEW, Veristand, Teststand, and other integration platforms the system is developed to have accurate data interpretation

Matlab / Simulink models can be integrated on NI RT platform to get precise data for next-level analysis.

With integrated CAN, and CAN FD protocols for comprehensive data exchange, the system ensures data integrity and security. As a control mechanism by implementing robust protection circuits, active cell balancing techniques, and adaptive control algorithms efficient energy management is achieved

Conclusion: The comprehensive integration of sophisticated monitoring, precise calculations and robust control mechanisms in the Battery Management System (BMS) for electric vehicles is essential. This holistic approach ensures enhanced safety, efficiency, and reliability.

2. Battery Pack Tester

The Battery Pack Tester utilizes advanced technology from National Instruments and other hardware components to provide comprehensive monitoring and testing solutions for battery systems. Designed for various industries, our Battery Pack test system ensures the safety, reliability and efficiency of battery operations. It uses CAN communication which speeds up the testing time.

Tests conducted:

  • Monitor Cell and Battery Pack Voltage – Measure voltage levels across individual battery cells to ensure uniformity and detect abnormalities. Measure voltage of battery pack.
  • Monitor Cell Temperature – Track temperature variations within the battery system to prevent overheating and optimize performance
  • OCV Test
  • Insulation Resistance test
  • Fault Diagnosis: Identify and diagnose potential faults or malfunctions in the battery system for timely maintenance and repair
Battery Pack Tester

3. Solenoid Test system

A solenoid works by producing electromagnetic field around the core.
Application Summary :-
Solenoid under test will be mounted on Mechanical assembly Provisions will be made in panel, to connect solenoid with test instruments during testing automatically. Provisions will be made to conduct following tests : 1. Diameter Test, 2. Resistance test, 3. HV test , 4. PE conductor Test, 5. Capacity test Test instruments will be interfaced with PC over RS 232 communication port. Digital Field-inputs and outputs will be connected to PLC , which will be interfaced to PC via MODBUS Ethernet.
Key Points :-
1. System is used to measure data in real time
2. An insulation resistance (IR) test measures the total resistance between any two points separated by electrical insulation. The test, therefore, determines how effective the dielectric (insulation) is in resisting the flow of electrical current.
3. Application software will be developed using NI LabVIEW development environment.
Benefits Achieved :-
1. Reduced Data Loss
2. Achieved Desired Cycle time
3. Flickering issue solved
Solenoid Test System for Electric Vehicle Industries by TMCS

4. Endurance Test – BLDC Motors

The test assembly consist of number of control configurations, controllers, and PC based data acquisition system
Application Summary :-
1. Monitors and tests Multiple Units simultaneously
2. Capturs total 60 channels if all 12 devices under test are connected
Key Points :-
1. Parameters like Voltage, Current, Power, Short Circuit current, Over Load/No Load voltages, Winding losses can be tested on same test bench.
2. 11 energy meters and 12 RPM meters will communicate with the LabVIEW based customized software.
3. High speed RPM & Frequncy measurement carried out.

5. Gear Rolling Tester

This system is used to measure and analyze the functional performance of gears. Composite errors in gears are the main parameter to evaluate the grade of the manufactured gears. Gear testing is a technique that has been used by the Industry to identify the manufacturing defects in the gears. System consists of mechanical assembly, Servo Motor and Drive. NI DAQ hardware, other sensors and PC with application software. Gear under test is mounted on Mechanical assembly and engaged with the Master gear that is mounted on spring loaded assembly This assembly is used to capture deviations / uneven surface, High Spot of gear. LabVIEW based Application software will acquire real time data, logs and analyse real time test data, display result and even mark hot spots on gear.

related solutions

We cater to diversified sectors with industry specific integration solutions. Our systems are reliable and sustainable. Robust reconfigurable and flexible engineering design helps our clients to achieve the better efficiency and throughput from these test systems.