Series
E-Motor Emulator
ATE system for motor control unit validation
E-Motor Emulator AMS replicates the four-quadrant electrical output of induction motors, 3-phase synchronous motor and range of motor types with user-defined profile including speed, torque and operation conditions to validate motor control unit. The system is an integrated testing platform with also battery emulation functions, support connecting the control unit from both AC and DC buses to serve as an ATE for end-of-line testing. The system replaces traditional motor dynamometer with advantages of safety, controllability, reduced cost and versatility to simplify MCU testing and validation. Highlighted Features
- Multiple motor characteristics in a single set of system with dynamic operating pattern (voltage, speed, thermal variations, inductance, etc) by user defined criteria
- Integrated battery emulation function supports power re-circulation between emulated motor and DUT to save testing cost
- Safe emulation of extreme operating conditions without actual physical risk of a real motor that may harm the control unit or devices involved in the test
- Resolver emulation, user-configured torque, speed, load and locked-rotor modes setting
Model Options
Find the right specification for your requirements
AMS E-Motor Emulator is a bespoke ATE system down to your specific testing requirements. Consult ActionPower team for technical details and model nomenclature.
Circuit and Topology
Highlighted Features
AMS E-Motor Emulator is of both AC and DC channels to simulate motor and battery characteristics respectively serving as an integrated testing system powering the buses of MCU at two sides with dynamic emulation and user configured parameter settings.
Permanent Magnet Synchronous Motor Simulation
| Parameters | Range |
|---|---|
| Stator d-axis inductance Ld (mH) | 0 – 2 |
| Stator q-axis inductance Lq (mH) | 0 – 2 |
| Stator resistance Rs (Ω) | 0 – 5 |
| Magnetic flux (V·s) | 0.005 – 2 |
| Rotational inertia J (Kg·m²) | 0 – 1 |
| Friction coefficient F (N·m·s) | 0 – 0.5 |
| Number of pole pairs P | 0 – 16 |
AMS E-Motor Emulator simulates a PMSM by running its electrical and mechanical equations in real time and using programmable power hardware to reproduce the exact current/voltage waveforms at the motor terminals. This allows developers to test motor controllers safely and flexibly without a physical motor.
Power Hardware Interface
- Four-quadrant bidirectional amplifier sources/sinks current to reproduce PMSM terminal V/I.
- Connects to the DUT exactly like a motor: three phases (and optional sensor feedback).
- Fast current/voltage loops ensure realistic transients and stability under controller tests.
Configurable Motor Parameters
- Pole pairs, \(R_s\), \(L_d/L_q\), flux linkage \(\psi_f\)
- Mechanical inertia, friction, and load torque profiles
- Thermal/derating and parameter drift (optional)
Faults & Transients
- Torque steps, speed ramps, and load disturbances
- Sensor offsets (resolver/encoder), phase loss/short, DC-bus dips
- Parameter variation to emulate heating/aging
User-Defined Loading Emulation Criteria
| Mode | Function | Key Parameters |
|---|---|---|
| Speed Mode | Simulator regulates motor speed according to setpoints. |
|
| Torque Mode | Simulator applies torque; the controller under test regulates speed. Supports three load models. |
|
| Locked-Rotor Mode | Simulates locked-rotor conditions for fault and start-up scenarios. |
|
Battery Simulation Functions
The AMS E Motor Emulator integrates a built-in battery simulation function, supporting a wide range of chemistries including lithium manganese oxide, lithium cobalt oxide, lithium iron phosphate, nickel-metal hydride, ternary lithium, lithium titanate, and lead-acid batteries.
It allows flexible configuration of series/parallel cell arrangements and enables parameter customization for temperature, state of charge (SOC), internal resistance, and capacity. The system supports 1st-, 2nd-, and 3rd-order RC equivalent circuit models with user-defined settings, providing accurate replication of battery pack charge/discharge behavior under various operating conditions.
Resolver Simulation
Resolver simulation allows adjustment of pole pairs, gain, phase, and installation angle, with fault injection for excitation/modulation open/short circuits, amplitude anomalies, and sine/cosine phase errors.
Feature-Rich Host PC Programming Interface
The system supports up to 200 programmable steps with as many as 999 loops. Output parameters—including voltage, current, and power—can be programmed according to user requirements using Step, List, or Wave modes. These modes can be combined to create complex test sequences for advanced applications. Programming data is non-volatile, ensuring persistence after power cycles, and supports convenient import/export for configuration sharing or backup.
Applications of AMS
E-Mmotor Emulator for Vehicle Drivetrain Validation and Testing
The integrated motor and battery simulator is designed for end-of-line testing, providing a reliable substitute for actual hardware.- Motor Simulation: Emulates real vehicle motors to evaluate motor controller performance across various operating parameters, ensuring safe and repeatable testing without the need for physical motors.
- Battery Simulation: Replaces conventional battery packs to supply controlled energy to motor controllers, while also supporting charging simulation under regenerative braking conditions.
Specifications
The following specifications are subject to modifications and changes without notification in advance. All specifications measured are at product's maximum ratings, if not otherwise noted.
| INPUT PARAMETERS | |
|---|---|
| Grid Phase | 3φ3W+PE |
| Input Voltage | 380V+10% |
| Input Frequency | 50Hz +3Hz |
| Power Factor | 20.95 |
| Total Harmonic Distortion (THD) | s5% |
| BATTERY SIMULATION PARAMETERS | |
|---|---|
| Rated Power | 150 kW |
| Peak Power | 200 kW (10s) |
| Voltage Range | 50–1000 V |
| Rated Voltage | 300 V |
| Rated Current | 500 A |
| Voltage Accuracy | ±0.1% FS |
| Voltage Ripple | ≤0.2% FS |
| Battery Types Supported | Ternary lithium, LiFePO4, LMO, NiMH, and other 7 common chemistries |
| Custom Battery Models | Supported |
| PROTECTION FEATURES | |
|---|---|
| Protection | Over-voltage, over-current, over-temperature, and emergency stop |
| ENVIRONMENTAL AND GENERAL PARAMETERS | |
|---|---|
| Operating Temperature | -10°C to +40°C |
| Storage Temperature | -20°C to +70°C |
| Relative Humidity | ≤90% RH at 25°C, non-condensing |
| Altitude | ≤2000 m |
| Protection Level | IP21 |
| Cooling Method | Water cooling (external deionized water, resistivity ≥2 MΩ·cm, inlet temperature 30°C, pressure 0.3 MPa, flow >50 L/min) |
| PERFORMANCE METRICS | |
|---|---|
| Response Time | ≤2.5 ms (10% to 90% step load) |
| Switching Time | ≤5 ms (+90% to -90%) |
| PROGRAMMABLE CAPABILITIES | |
|---|---|
| Simulation Modes | Supports general, step, ramp, fixed battery type, and custom battery/motor simulation modes |
| MOTOR EMULATION PARAMETERS | |
|---|---|
| Number of Phases | 3 |
| Rated Power | 150 kW |
| Peak Power | 220 kW (20s) |
| Max Line Voltage | 450 Vrms |
| Max Current (rms) | ±560 A |
| Rotation Direction | Clockwise / Counter-clockwise |
| Test Speed | 0–15,000 rpm |
| Acceleration Time | <3 s (0 to 15,000 rpm) |
| Test Torque | Based on actual current and motor parameters |
| Pole Pairs (Resolver) | ≥2 (configurable) |
| Resolver Excitation Peak-to-Peak | <30 V |
| Resolver Excitation Frequency | 3 kHz – 10 kHz |
| Current Frequency | 0 – 1 kHz (≤10 kW at 1 kHz) |
| Stator Resistance | 0–5 Ω |
| Motor Type | PMSM |
| Position Sensor | Resolver |
| Additional Features | Condition simulation, current calibration, locked-rotor simulation (configurable angle) |
| Continuous Current (rms) for 6-hour operation |
500 A (<50 Hz) 400 A (<100 Hz) 340 A (<150 Hz) 270 A (<200 Hz) 220 A (<333 Hz) 180 A (<500 Hz) |
| INTERFACES | |
|---|---|
| Model Interfaces | Custom 1st, 2nd, 3rd order model interfaces |
| External Emergency Stop | Supported |
| Communication Interfaces | CAN, RS485, LAN |
| Communication Protocols | Open protocols for host PC and third-party integration |
| Power Monitoring | Integrated functionality |
| ISOLATION | |
|---|---|
| Topology | Bi-directional isolation topology ensures electrical isolation between grid and DUT, supporting two-way energy flow |
| DIMENSIONS | |
|---|---|
| Size (W×D×H) | 2410 mm × 1200 mm × 2100 mm (+100 mm tolerance acceptable) |
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