Design and Experimental Evaluation of a Scaled Modular Testbed Platform for the Drivetrain of Electric Vehicles

Electric vehicles (EVs) are experiencing explosive growth in public adoption, causing a major shift in research and development priorities by OEMs toward electrified powertrains. To verify EV drivetrain platforms and software models in the design phase, testbeds with specific capabilities are essential. Full-scale vehicle testbeds are expensive, bulky, dissipative, and not easily reconfigurable or movable, making scaled testbeds more attractive, especially for education and research institutes. To support this cause, this paper reports on the development of a small-scale, modular, hardware-in-the-loop (HIL) testbed platform for the drivetrain of EVs that is cost-effective, efficient, and easily movable and reconfigurable and allows integration of a battery pack. The testbed is comprised of two directly coupled electric machines. The first machine emulates the traction motor and is used to control vehicle speed according to a specified drive cycle. The second machine is used to impose a torque profile on the first machine’s shaft—based on the vehicle’s parameters and driving environment—and emulates a gearbox (if necessary). A systematic two-way scaling approach is adopted to downscale the parameters and driving environment of full-size EVs to a level that can be handled by the testbed and to upscale the test results obtained from the testbed to the full-size vehicle level. The power consumption of the testbed is limited to system losses. A case study involving a full-size EV was performed and the HIL simulation results were compared to the computer simulation results to verify the performance of the testbed.