The interaction of electric, electronic (E/E) and mechanical components defines the quality of a BEV’s powertrain. Component selection, their integration and calibration aim at meeting legal requirements for EMC and safety as well as competitive targets for efficiency, NVH and driving comfort. These tasks in particular need attention on electromagnetic events on the DC bus, the high-power electronics of inverters, the e-motors, and the drive shaft. Each component within this environment is defined by its electromechanical features with variabilities selected from a large set of operating parameters. Consequently, a complete powertrain and its controllers give rise to endless combinations for powertrain operation. How to understand and avoid risk laden and ineffective parameter options, how to find powertrain control parameters for safe, efficient and comfortable operation? And how to find solutions within competitive development timeframes? Particular issues include high voltage risks on AC and DC bus, AC resonant ripple currents on the DC lines, or risks arising from powertrain dynamics and impacting NVH quality and driving comfort. Such issues are addressed with extensive system simulations and, finally, with comprehensive testing a powertrain’s electric, electronic and mechanical behavior. The focus of this paper is on E/E and NVH signal analytics guiding the integration of powertrain modules:
E/E challenges arise from voltage bursts at MHz frequencies endangering insulation of stator windings and cables.
Current ripples on the HV-DC bus may endanger auxiliary components.
Motor operation and drive shaft dynamics must not compromise NVH quality and component durability.