Calibration of an Electric Drive Unit Test Bench Using an In-Vehicle Control Mapping Methodology for High-Power Applications

This paper presents a comprehensive methodology for mapping and controlling interior permanent magnet synchronous motors (IPMSMs), with a specific focus on their application in electric vehicles (EVs). This study details the acquisition of current mapping data from an IPMSM of an EV under various operating conditions. The sweep of the full-range speed and torque test points was performed on a chassis roll dynamometer for the in-vehicle electric drive unit (EDU) of a 170 kW Polestar 2 EV. The vehicle was instrumented to collect the essential data using synchronized data acquisition (DAQ) systems along with vehicle's controller area network (CAN) bus. To validate the effectiveness of the proposed methodology in real-world scenarios, experimental tests and calibration were performed on a motor test. Only the motor is removed from the vehicle and a custom inverter/controller with a battery simulator and cooling system was installed to bypass the proprietary access restrictions of the original equipment manufactures (OEMs). After processing, the dataset extracted from the dynamometer test is subsequently integrated into a lookup table (LUT) based field-oriented control (FOC) strategy. The experimental tests performed on the motor test bench demonstrate the efficacy and practicality of the methodology, successfully validating its applicability in four-quadrant operation.