Engine simulation with the Kewell M2000

Goal and tasks of engine simulations

When developing electric drive systems, the tests must be accurate, reliable and reproducible. This applies in particular to inverters, i.e. the electronic control units of electric motors. With the M2000 series, Schulz-Electronic offers a powerful motor simulation solution from Kewell that realistically replaces electric motors without having to use mechanical components such as the motor or dynamometer test bench.
By using mathematical models for synchronous and asynchronous machines, dynamic driving situations, load cycles and faults can be accurately simulated. This improves the depth of testing, lowers costs and reduces the complexity of the test benches.

Applications and challenges

Engine simulation is used in the research and development of inverters (engine control units) and for testing control units in automotive engineering, aviation, industry, for series test benches and end-of-line tests (EOL) as well as for long-term and ageing tests under dynamic load conditions.

Challenges with conventional test setups:

Use of complex test benches with real motors, gearboxes and load machines
Lack of reproducibility of dynamic scenarios
High energy consumption, noise level and maintenance costs due to mechanical components
Fault simulation only possible to a very limited extent.

Mechanical test benches are still useful in system integration, but fully electronic simulation solutions such as Kewell's M2000 system offer a scalable, reproducible and significantly more efficient alternative, especially for development, validation and EOL testing. Thanks to the significantly reduced space and cost requirements as well as the possibility of being in the same room as the test object during the test, the M2000 system from Kewell offers a particularly efficient and user-friendly solution for modern test environments.

The Schulz-Electronic range for engine simulation

With the M2000 from Kewell, Schulz-Electronic offers a system solution that simulates the electric motor as standard and optionally also integrates battery simulation.

1. M2000 electric motor emulator (standard version)
This variant replaces the electric motor in the test bench. The inverter is supplied by a separate battery simulator.

Simulation of synchronous and asynchronous machines
“Current Response”: up to 1500 A/ms, frequency up to 2 kHz
Simulation of typical error cases: blocked rotor, short circuit, sensor error
Encoder signals (ABZ), resolver and temperature simulation included
Modularly expandable (100 kW to 600 kW power class)

2. M2000 with integrated battery simulation (all-in-one configuration)
For EOL tests, Kewell also offers a system configuration in which the battery simulator and motor simulator are integrated in one housing. This configuration is particularly suitable for quick functional tests in series production.

Two separate outputs:
> DC output for battery simulation (for the input of the inverter)
> AC output for motor simulation (replaces motor and load)
Saves space, reduces cabling effort and system complexity
Supports typical test processes such as ageing test, current calibration and operating point verification

Test scenarios that can be carried out with the M2000 series:

Functional testing: research and validation of control unit functions before integration
Dynamic tests: acceleration and braking profiles, load changes, high-frequency behavior
Fault simulation: CAN signal errors, sensor failures, short circuits, demagnetization
EOL test: series-accompanying quick tests with configurable profiles
Ageing test: Continuous operation with realistic profiles and automatic evaluation