Electric Power Testing - From Component to Vehicle Energy Management

Electrification of aircraft offers travelers the possibility of more efficient, silent and ecologically sustainable flight. For aircraft operators, it means reductions in fuel consumption and operating costs. The new source of power for flight introduces new possibilities for both engineering and economics:

• electric motors and computerised inverters already deliver the power density necessary for flight
• flight range is (currently) determined by the weight of the energy source (battery)
• electric motor volumes are smaller, permitting new STOL and VTOL designs.

We provide complete systems for motor test benches, including sensors, instruments and software for ‘iron bird‘ testing of airframes, flight control, digital network buses and electrical or hydraulic actuators.

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Electric powered vehicles are gaining not just attention but also a larger share of the market. And there’s something for every segment of the market, too:

• economic sub-compact city cars that achieve over 18km per kWh
• classic four seat four doors with a payload over 400 kg
• company cars for business trips and a range over 400 km
• performance cars with 0-60 times under 6 seconds.

And they are all thoroughly tested – to validate the design before going into production and to ensure quality standards are met during production.

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As hybrid and electric vehicles become more widespread, the network of charging stations becomes increasingly important. These must not only be energy-efficient and cost-effective, they must also be safe in all situations:

• from low- to high-voltage, they must serve all vehicles effectively
• in summer heat, through sub-zero winters they must function in all weathers
• they must withstand liquids from rain to aggressive chemicals
• they must function flawlessly no matter how they are pulled or twisted.

Charging stations and their cables that meet high demands of the quality, longevity and resistance to abuse have been rigorously tested to ensure that they perform effectively throughout their lifetime. Our solution helps verify the reliability of cables in charging stations - a special, yet significant, contribution to the future of electromobility.

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Test bench engineers need to understand the performance of an electric drive and its losses within minutes, R&D managers want to shorten the test bench cycle, and product developers want a faster time-to-market. That’s why they choose HBM’s best-in-class sensors, instruments and software that are used for:

• Electrical Machine and Powertrain Testing
• Grid Testing
• Electric System and Inverter System Testing
• high Voltage and Switchgear Testing.

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Electric traction is widely used around the world, especially for urban and suburban railways that have dense traffic or high-speed lines that need electric traction to obtain the speeds required for long distance and inter-city travel. Testing of the key components and systems for rail transport includes:

• efficiency of the inverter / rectifier and motor both as components and as a system
• the safety and efficiency of the pantograph or electrified third rail
• performance of the overload relays which protect the motor from power spikes
• correct functioning of the electromagnetic relays that connect the motor units with the driver control lines.

We provide equipment for all aspects of electric railway traction, control and performance.

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Whether on-shore or off-shore, wind turbines usually operate under harsh conditions in remote locations. Maximum efficiency is achieved by combining reliable components into durable systems that require a minimum of maintenance and downtime - all design choices must be rigorously tested and validated:

• static load and fatigue tests ensure safe operation for rotor blades
• fast, accurate data acquisition for analysis of high voltage generators and inverters
• efficiency testing for gear units to ensure long service life and minimum wear
• mechanical and electrical measurement of complete nacelle test stands to maximise service life.

We provide testing and measuring equipment for longer service life and higher efficiency.

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By 2030, demand for electricity will grow 200% globally - in developing countries it grows by 300%. As the need for reliable power generation increases, the ability to maintain complex power plant equipment becomes even more important:

• Corrective and preventive maintenance must be performed with minimum downtime
• Regular 1st level maintenance must be followed up with troubleshooting
• Advanced maintenance requires documented testing, monitoring and diagnosis
• fault-finding in critical areas must include NVH and mechanical as well as electrical issues.

We provide sensors, instruments and software for accurate data acquisition rapid analysis and visualization of results across all types of signals.

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A microgrid is a group of electricity sources and loads that is normally connected to a traditional wide area synchronous grid - but it can also disconnect to ‘island mode‘ and function autonomously as physical or economic conditions dictate. There are many reasons for microgrids:

• communities or villages in remote locations, powered by alternative energy sources
• business models that are built on the premise of continuous availability (like data centres)
• social services such as hospitals that cannot function without a guaranteed power supply
• a self-contained, temporary installation such as a disaster relief centre (after flood, hurricane, etc.).

We provide test and masurement solutions that scale for any type of Microgrid – from DC to high-voltage, from mV to MV and hundreds of thousands of amps.

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The power density of electric motors has reached a decisive tipping point. They are increasingly being adopted for a wide range of applications where the noise and fumes of diesel engines are no longer welcome:

• last mile delivery vans and commuter busses for inner cities
• emission-free work at indoor construction sites, warehouses or underground mining
• silent work in built-up residential areas or during night shifts
• long-distance trucking for lower costs and maintenance.

We support engineers not only at the design and quality control stage, but also with continuous condition monitoring, data storage and analysis equipment for planned preventive maintenance.

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Increasingly stringent MARPOL regulations, plus national emissions directives create new challenges for the shipbuilding industry worldwide. At the same time, electrification brings opportunities for greater efficiency:

• new designs for hybrid and electric propulsion systems deliver greater efficiency
• on-board monitoring via precise load measurement in the power train reduces fatigue and minimises downtime
• ‘cold ironing’ enables ships to connect to the grid when in harbour and reduce emissions.

Our solutions for marine applications range from analysis of components, through structural testing of stress and fatigue to function and component tests for optimizing engines and performance.

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Lifting is one of the basic industrial tasks that appears in just about every sector you can think of. Not just transportation of goods, but also the movement of people in buildings via elevators, moving walkways and escalators. Electric motors, inverters and controllers for such applications share characteristics like:

• high torque output for steadying and supporting heavy loads
• high-speed control system to enable precise positioning of the loads
• in-built system monitoring for ongoing data collection and analysis
• simple, robust design to minimise maintenance and repair downtime.

We provide sensors, instruments and software for validation of design at the test bench and for continuous monitoring to meet operational and safety standards.

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