UNICO Teststand Overview

Innovative Motion Control Solutions
for Industry

Worldwide Offices and
Alliance Partners
Franksville, WI Canada England Germany
Michigan Venezuela Peoples Republic of China Japan

Unico Test Stand Expertise
• Application Knowledge / Extensive Installation Base
• High Performance AC Drives with Wide Power &
Voltage Range
• AC Motors designed for Special Applications
• After Sales Market Support
• Major Production bases in USA, UK, Germany & Japan
• Worldwide Application and Service Support

UNICO Invertor Drives
Digital / Self-Tuning / Intelligent /
1.0 - 1250kW/ 230, 460, 575, 690 v

Test Stand Drives – 2400 Series
Exceptional Performance
Comprehensive Power
Range
Extensive Dynamometer
Software
Complete Test Stand
Applications

Test Stands & Dynamometers
• Development, endurance, and production testing
• Automotive engines (Petrol/Gas/Diesel)
• Brakes & Clutches
• Power train and Transmissions (Gearbox, Transfer
Case, CVT, IVT, Hybrid, Axles)
• Complete vehicles (Chassis dynos)
• Electric vehicles
• Racing/Performance cars
• Hydraulic pumps
• Engine accessories FEAD
• Aerospace testing

Unico Exceptional Performance
• Extensive development capabilities
• Power range up to 1,250 KW
• IGBT switching up to 20 kHz
• Output frequency up to 1,500Hz
• Torque settling time average 2 ms
• Acceleration rates up to 300,000 rpm/second
• Motor speeds up to 24,000 rpm
• Torque estimator < 0.5% accuracy of max torque
• Mixed mode at low speed
• Dual Fast Vector Rotator at 280MHz
• NVH Low noise speciality

Unico Drive Software
• Test Stand embedded software – Main DSP
• Main DSP software – 280 MHz
• Fast vector Rotator – 280 MHz
• UEdit®– soft PLC
– For auxiliary functions
– For logic functions
– Drive function monitoring
• Drive Monitoring
– Drive Keypad on each Invertor
– Drive link (drive management software for Windows®)
– Interface to LapTop or PC

Unico Drive Performance (A)
• Torque Analogue input rate 100 µs
(at 10kHz IGBT switching)
• Torque estimator – options
– Standard ±2% of maximum torque
– Optional ±0.5% of maximum torque (Asynch and Synch)
• Dynamic torque control
– 0.6 ms Rising time up to 90% torque
– 2 ms average settling time
– No increased times in field weakening range
• Current loop
– Cycle (sampling) time - 100µs (at 10kHz IGBT switching)
– Sampling time – current command analogue/field bus - 100µs
• Current Loops:
– Digital, Space Vector, Sine Triangle

Unico Drive Interface
• Analogue I/O
– 12 Bit (standard), 14 Bit (standard) and 16 bit (optional)
– 0/10 volts, ±10 volts dc, optional of both
• Digital I/O
– 16 bit (standard), 32 bit (optional)
– Mixed I/O with Form A, Form C and open collector
– Some isolated inputs and contact outputs
• Serial communications
– Remote I/O, Modbus plus, Control Net, Profibus, Ethernet
– CANopen and CAN raw, DeviceNet, Interbus, LonWorks
– Fibre Optic (Unico Dynlink and Dynlink plus)
• Torque transducer, Load cell (voltage or frequency)
• Velocity feedback
– Incremental, Absolute, SinCos and Resolver

Energy Saving Common DC Bus
3-Phase AC
Power Input
DC
BUS
Charging
Unit
+
_
Inverter 1
AC
Motor
Regenerative or
Non
Regenerative
Motoring (Engine)
Inverter 2
AC
Motor
One motor removing energy
from DC bus, the other
regenerating energy to DC bus
Energy re-circulated on DC bus so
that only minimal power required to
Supply losses drawn from AC mains
Inverter 3
Absorbing (Wheels)
AC
Motor
Absorbing (Wheels)
Example: Front or Rear Wheel drive Transmission Test Stand

UNICO Drive System

AC Motor Technology
• Asynchronous and synchronous motors
• Air cooled, water cooled, oil cooled and combinations
• Foot mounted and trunnion (swinging frame) mounted
• Thermal protection
• High speed precision, ball and roller bearings
• Insulated bearings and/or bearing housings
• Encoders for precision velocity feedback

AC Dyno Motors

Transmission
Testing

5 axis power train

Torque estimator

Torque estimator

Torque estimator wheel
25
20
15
10
5
10 20 30
Wheel motor: 0.5% of max torque = 30 Nm
Number of measurements: 68
Errors grater than 0.25%: 6
Errors grater than 0.50%: 2 ( 0.57% and 0.67% )
Vertical: Number of errors
Horizontal: Error in Nm.

Torque estimator input
Input motor: 0.5 % of max torque = 15 Nm
Number of measurements: 63
Error greater than 0.25%: 0
Error greater than 0.50%: 0
Vertical: Number of errors.
Horizontal: Error in Nm.

Support
• Telephone Support
• Field Service
• Start-Up Coordination
• Training
• Parts and Repairs
• Contract Engineers
Field Service
Training Phone Support Parts/Repairs

Support Tools
• UEdit integration tools
• DriveLink monitoring tool
• UBIT interactive training
• Uniscope PC oscilloscope
• Electronic Troubleshooting (ETS)
• Data Sampler
DriveLink
Uniscope
Data Sampler
UEdit

Test Stand Installations
(Transmissions)
Aisin, Akashi, Allan Gears, Asano Gears…..
Caterpillar Defence…..
Daimler Chrysler – Kokomo, Sterling, Orangeburg….
Dana Spicer – Orangeburg, Birmingham, Volkermarkt….
Ferrari…..
Ford – Dearborn, Livonia, Sharonville……
…….
GM – Allison, Yanti, , Daewoo, Flint, Silao, , Strasbourg
GM – Windsor, Ramos Arizpe, , Toledo, Ypsilanti, Warren
GM - Honda – Georgia, Giken Tochigi, North Carolina,
GM - Ohio, Swindon…..
Jatco – Farmington Hills, Okazaki, Atsugi…
JTEKT (Koyo Seiko) – Nara, Kokubu….
KIA, Metadyne, , New Venture Gears, ………..
Red Bull Racing, Renault, SSang Yong Motors……
……..
Ricardo UK Ltd, Suzuki, Torotrak, Yamaha, ..………
……….
Porsche, ZF, Horiba,…..

Benefits of UNICO
• Extensive Application Knowledge
• Cost Effective Solutions
• Reliability
• Flexibility
• High Dynamic Performance
• High Efficiency plus Energy Saving
• Power Supply Integration
• Full After Sales Support

UNICO – HIGH PERFORMANCE
TEST STAND SYSTEMS