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Siemens solutions for test stands

Siemens solutions for test stands

Understanding that research achievements must be rigorously checked and tested, and new functions meticulously verified to ensure effectiveness, the technical accuracy and flexibility of Siemens automation and drives solutions provide significant advantages for test stand applications. They also feature outstanding efficiency when it comes to energy, time and costs – and safety for persons in compliance with applicable local standards. As a one-stop complete supplier of electronic components and application-specific concepts, Siemens is ready to help implement your innovative concepts for test stands that are fit for the future.

Where do testing systems make the highest demands?

  • Drives
  • Inverters
  • Communication
  • Control systems
  • Planning 
  • Commissioning

What are the key requirements?

  • Accuracy
  • Repeatability
  • Safety
  • Flexibility

With more than 160 years of industrial application experience...

... it only makes sense that the world’s leading companies call on Siemens to assist in developing test stand systems. Whether the results are to verify specifications, to confirm manufacturing integrity (end-of-line), durability, reliability, noise, vibration, harshness (NVH), or any other kind of assessment, Siemens has the right products and expertise for any industrial test stand application.

 

One of the most common scenarios involves using a motor to provide a simulated load against the input force of the part being tested. For example, a durability test stand might be set up by an engine manufacturer to see how long an engine can withstand a specified torque. In this example, a motor controlled by a variable frequency drive would be coupled to the engine. The variable frequency drive would then be programmed to provide a resistance against the motor at a specified torque

18 good reasons to talk to Siemens

  • High response, accurate servo-like performance available for both motors and drives - SINAMICS S120 / S150 drives have a torque accuracy of 1.5% 
  • High-power DC modulation for electric vehicle powertrain testing
  • Speed and torque-consistency (low ripple)
  • Adaptable closed-loop system for maximum torque quality - rotating-field frequencies above 1000 Hz
  • Energy recovery for braking without dangerous current harmonics
  • Type tested and standard design common bus enclosed drive solutions
  • Ability to supply a power-matched motor / drive combination for custom test stand applications
  • As high as 6,000 Hp in a low-voltage design
  • Energy exchange in the coupled DC link for multi-axis test stands
  • Where multiple drives are required, a single control unit can control up to 6 drives – eliminating the need for drive-to-drive communicationEMC filters available to eliminate the possibility of noise interference with test stand sensors
  • PROFIBUS, PROFINET,  Ethernet I/P™ and Ethercat communications available 
  • Integrated safety functions, e.g. SLS on entering the test cell 
  • Smaller footprint drives and motors
  • Low speed, high torque motors are available to eliminate the need for a gear reducer 
  • Motors can be ordered with a KTY84 temperature sensor which is wired to the input on the drive. There is software built into the drive to use the temperature feedback to maintain torque accuracy even while the motor is heating up
  • Siemens drives have free function blocks that can be used to do “bumpless” transfer from speed mode to torque mode and also from torque mode back to speed mode
  • SINAMICS S120 Cabinet Modules are available with customized common bus lineups to minimize problems 
  • 12 pulse and 18 pulse drives solutions available
Applications

Advantages of a test stand featuring Siemens technology

Product selection

Components for the implementation of test stands

Interaction with the options of Totally Integrated Automation (TIA) and Integrated Drives Systems (IDS)

Both SINAMICS S150 and the S120 Cabinet Modules are high performance drive products. These products offer the best solution when speed and torque accuracy, and response are critical. Siemens has other lower performance, lower cost alternatives when the application does not require high performance. For example, a pump test stand or maybe an endurance test stand might not require servo level performance.

 

For those test stand OEMs preferring to build unique drive lineups, The SINAMICS S120 modular product is available as a loose chassis to be built into a custom enclosure. The S120 components offer the same performance advantages as far as accuracy and torque response as the S120 Cabinet Modules and SINAMICS S150. 

SINAMICS DCP DC/DC converters

  • Bidirectional buck-boost converter in a single device
  • High switching frequency
  • Can be connected in parallel
  • Can be connected to an Active Line Module

Realization of PROFINET for data logging and external control systems

  • PROFINET isochronous (IRT) for cycle times up to 250 µs
  • Ring topology for higher equipment availability
  • Software development kit available 
  • Includes source code
  • For different operating systems
  • CP1616 (PCI) or CP1604 (PCI-104)

User benefits

  • Reduction of interface converters
  • No EMC influences
  • Use of industry standards
  • Broad base of manufacturers
  • Simple integration
  • High performance due to rapid memory access
  • Consistent process data

Control unit CU320-2 DP/PN

Feature — Benefit

  • EtherCAT interface for option slot of CU320-2 DP/PN available
    — Integration of SINAMICS S120 drives in EtherCAT topologies, e.g. customer controllers/PLCs
  • Support of CoE (CANopen over EtherCAT) drive profile CiA DSP 402
    — Entire integration & easy migration (CAN-bus > EtherCAT)
  • Safety: all safety functions that run in SINAMICS S120, no FSoE
    — All safety functions available
  • Integrated webserver accessible through on-board PROFINET interface (parallel to EtherCAT) X127/X150
    — High usability and flexibility through user-defined web pages
  • Different motion control modes: Position control and speed control 
    — Flexibility and easy configuration
  • 2-port switch supports daisy chain topologies
    — Easy wiring and synchronous operation of multiple axes

PROFINET still offers additional advantages compared to EtherCAT:

  • IEEE-conformance, open standard, harmonic integration, diagnosis, safety…

Startdrive – perfect interaction in the system

Feature — Benefit

 

Efficient engineering

  • One single uniform engineering platform 
  • Common functionalities (trace, library, etc.)
    — Shorter training time, reduced engineering effort, automatic consistency within the project

Integrated drive control

  • SIMATIC Motion Control technology objects
  • Drive libraries
    — Drives can be simply connected to SIMATIC PLCs, motion control applications quickly and simple realized

Safety integrated 

  • Efficient safety commissioning 
  • Standard components with integrated safety technology
  • Integrated communication function block for SINAMICS Safety Integrated
    — Installation and commissioning even quicker, less Hardware / No additional components, greater flexibility for extensions and adaptations
Application-specific solutions

Steps away from the best tests

Let Siemens demonstrate the advantages of working with a solutions-focused company.

Drive line dynamic analysis 

  • Knowledge of bending critical speed in real construction

Multi body simulation 

  • Knowing oscillation frequencies

Benefit

  • Design optimization already in place during construction

Driveline dynamic analysis

FEM determination of bending critical speed

  • Performed by Siemens mechatronic support
  • Calculation considering the complete system
  • Long-standing experience

User benefits

  • Accuracy of bending critical speed
  • Design optimization in place during construction
  • Risk minimization  by assessing the overall design
  • Increased machine reliability

Multi-Body Simulation (MBS)

Calculation of torsion oscillations

  • Performed by Siemens APC
  • Calculation considering the complete system
  • Long-standing experience

User benefits

  • Definition of oscillation frequencies
  • Design optimization in place during construction
  • Risk minimization 
  • By assessing the overall design
  • Increased machine reliability
  • Reduction of commissioning time
  • Optimal dimensioning of entire powertrain
  • Less wear

Fast dimensioning — from the requirement to the solution

  • Guided configuration by deposited mechanical systems
  • Integrated database with all motors and drives
  • Integrated dimensional drawing generator
  • Mechanical rack system, wiring diagram, and parts list
  • System reaction consideration
  • Thermal analysis of the application
  • Consideration of pulse frequency, dynamic, system effectiveness, supply fluctuations, traversing profiles and mechanical counter torque
  • Performance evaluation of the control unit
  • Support of different grids

User benefits

  • Configuration guaranteed by technical evaluation of the application
  • Fast selection of drive components
  • Free download
  • Web version online

Fast dimensioning — from the requirement to the solution

  • Guided configuration by deposited mechanical systems
  • Integrated database with all motors and drives
  • Integrated dimensional drawing generator
  • Mechanical rack system, wiring diagram, and parts list
  • System reaction consideration
  • Thermal analysis of the application
  • Consideration of pulse frequency, dynamic, system effectiveness, supply fluctuations, traversing profiles and mechanical counter torque
  • Performance evaluation of the control unit
  • Support of different grids

User benefits

  • Configuration guaranteed by technical evaluation of the application
  • Fast selection of drive components
  • Free download
  • Web version online

Openness for external set point sources

  • Efficient integration of customer models of MATLAB SIMULINK & C++ or LabVIEW

Open architecture for technology functions

  • Example: combustion engine simulation in current control clock (e.g. 31.25µs) without additional hardware

Benefit

  • Customer loyalty through openness and control performance

SINAMICS S120 software extensions for test stands

Standard SINAMICS S120 firmware function

  • Constant torque and speed
  • Learning phase for the identification of cogging
  • Pre-control of cogging 
  • Periodicity configurable -> external disturbance torque
  • For torque or linear motors

 

User benefits

  • Optimal test results
  • Constant torque also at low speeds
  • Reduction of speed ripple in permanent magnet synchronous motors (PSM)

SERVCOUP – proven with Siemens linear motors and high speed 3rd party motors

  • Coupling of SINAMICS S120 motor modules with only one encoder in servo control mode
  • Substitution for encoder splitters
  • Multiple servo controllers are digitally coupled within the CU
  • Master-slave coupling on base of torque setpoint realized
  • Speed controller with encoder connection only required on the master axis  

User benefits

  • Coupling of several motor modules in servo control mode possible
  • Increase of current to reach higher torque
  • Splitting the windings of one motor allows use of higher pulse frequencies

Integration of MATLAB SIMULINK models in SINAMICS and SIMOTION

  • SIMOTION C, D, P (up to 250µs)
  • SINAMICS CU320-2 (up to 1ms)

Create drive level control blocks based on MATLAB models.

 

Source code generated from the Simulink Model is integrated in a DCB Studio project. A DCB library is then generated. This library can be installed in Starter, and is exclusively available for programming Sinamics drives.

 

User benefits

  • Rapid compilation of control structures
  • Programming out of the simulation
  • Free targets for Matlab SIMULINK
  • Automatic coding
  • No C / C++ know-how required
  • Optimized workflow
  • Time saving by simulated controller
  • Reduction of commissioning time
  • Easy, graphical programming

Torque Pulse Simulation (TPS) with TEC Polygon

  • Mathematical signal generator based on user-defined value table (cam function)
  • Up to 10,000 interpolation points possible
  • Comprehensive dynamic functions: Amplitude, offset, scaling and leading value offset adaptable
  • Output signal Y is dependent on leading value X (e.g. encoder actual value, position, electrical angle)  and the parameterized characteristics   

User benefits

  • Realistic test
  • No engine conditioning
  • Considerable noise reduction
  • No fuel consumption
  • Attachable torque profiles for different engine types
  • Excellent torque precision
  • Usable without superimposed control
  • Very fast setpoint setting

LECo – Automatic disturbance compensation

Automatic disturbance compensation of large engine cold test stands

  • Self-learning compensation
  • Usually learned after 4 – 6 periods
  • Quality criterion = a constant speed
  • Fault detection over non-periodic disturbing moment -> Speed deviation
  • Simotion Controller function

User benefits

  • Few parameter settings necessary
  • Optimal bad engine recognition
  • Fast teaching of new engine types
  • No external measuring technique required

SetPGen

  • Set point generator consists of three separate signal generators — sine-wave, saw tooth, square-wave signals up to the 3rd order harmonic
  • Amplitude, frequency, phase offset and offset can be changed during runtime 
  • Signal frequencies up to 1.6kHz at rate of current controller clock (62.5 s)

 

User benefits

  • Internal drive function
  • Usable without a superimposed control
  • Very fast setpoint setting
  • Connectable as additional torque or additional speed
  • Use for periodical disturbance compensation

Sample test stand application diagrams

Battery simulation with SINAMICS components

Battery simulation with SINAMICS components – alternate

Task

  • E-mobility calls for the vehicle inverter to be tested
  • Trend towards higher voltage and voltage constancy without ripple

Solution

  • Integration of battery simulation into the SINAMICS S120 drive system
  • Scalable enclosed DC systems

Benefit

  • Energy exchange with dyno in DC-Link
  • Compact footprint with reduced complexity
  • No DC filters needed 

Products used:

Battery simulation with SINAMICS components

Task

  • Battery or fuel cell test
  • Trend towards higher voltage and voltage constancy without ripple

Solution

  • Integration of functionality of a variable DC source into the SINAMICS S120 drive system
  • SINAMICS TEC DCDCCONV
  • 1000VDC with 690VAC

Benefits

  • Energy regen to grid during discharge
  • High dynamic DC converter
  • Common hardware platforms

Products used:

Hot

Test for function and proper seal before engine is mounted in a vehicle
 

Motor is run on its own power until specific oil temperature is reached

  • Without, or with incrementally increased motor loads

Key data for a production check are measured, monitored, and documented

  • Speed and torque
  • Oil pressure and temperature
  • Cooling water temperature and flow
  • True running, ignition, injection time, oil turbidity, emission values, etc.

A short performance test is carried out at the end of the warm-up phase

 

Operator checks motor for abnormal noise and leaks

 

Cold

Tests internal combustion engines directly on the assembly line

 

Motor is powered electrically rather than with fuel – much greener

 

After leak test, motor is filled with oil and fuel where required

 

Test results demonstrated compliance with quality requirements

 

Products used:

User benefits

  • Reduction of transformer performance
  • Reduction of the line module
  • Environmental protection by intelligent energy management

Products used:

or

UL compliant

User benefits

  • Safe operation of the test bed at short grid interruptions and external disturbances
  • Reduction of the transformer performance and energy costs
  • Effective dimensioning of strongly cyclical drive systems
  • Reduction of the line module
  • Environmental protection by an intelligent energy management
  • Easy installation by insertion technique
  • 6SY7000-0AE64 SINAMICS capacity module 132mF 

Products used:

or

Task

  • High precision roller rigs with constant torque (no ripple)
  • Improve stiffness of the system to eliminate inaccuracies

Solution

  • Compact style using direct motors SIMOTICS T-1FW3
  • Energy exchange with common DC bus

Benefit

  • Noise minimization by water cooling and variable switching frequency
  • Drive integrated gearing

Products used:

or

Success

Test stands in practice

Customer experiences

Contact

Find your local Siemens test stand specialist

To answer any questions about products and solutions