5min and 30min electric drive train testing

Test Date: 2017.12.11 by Vito Ho, Liang yupeng,Ruan qunchao,Judy Gong, Zhang ying Ambient temp: 12.1C, Humidity: 61%, Pressure: 102.6kPa
Pictures for refernce Motor
Insert thermocouple inside of motor
Monitor side cover temp and take note
Performance curve
1211 1kw205 35HV1 phase59 battery48 in 5min

1211 1kw205 35HV1 1.2kw continous 30min test 3rd
31N.m,362.3RPM,1178W last in 30min.
Test record

Test Date: 2017.12.13 by Vito Ho,Liang xianjiang, Zhangying
Ambient temp: 12.3C, Humidity: approx 35%, Pressure: approx 102.6kPa
1st step, to find most suitable setting of controller, with the condition battery current less
than 50A.
We did some test.
1st test Phase current 59%, battery current 37%
maximum battery 48.47A, maximum torque 95.6N.m,

2nd test Phase current 59%, battery current 38%
maximum battery 49.45A, maximum torque 100.4N.m,

3rd test Phase current 100%, battery current 23%
maximum battery 51.9A, maximum torque 99.4N.m,
In this test, we make full phase current, but it don't help on the torque.
We measure it by tong-type ammeter, and get 80A maximum, which is RMS current.
So the peak might be 80*1.414=113A, then we set 52% in next test.
Which means the motor couldnot bear more phase current (less than 59%).

4th test Phase current 52%, battery current 43%
maximum battery 50.72A, maximum torque 97.8N.m,

2nd step, make net power test,
setting Phase current 59%, battery current 38%, refer to attached "12 13 59 38 1st 完整测
试 记录温升".
but I found the battery current is 51.44 (over 50A), It seems the battery current ranges a bit.

Then I modify the setting, and our workmate turn the throttle a bit during the modification.
And we found the controller break down (with the red led turn on).
After checking with Fany, the controller is dead.

We have some KLS4812S controllers in store. And could do more test later.
Test Date: 2017.12.16 by Vito, Liang xianjiang,Huangjie
Ambient temp: 9.8C, Humidity: 64%, Pressure: 102.9kPa
Last time, the Kelly controller KLS4812S was broken after throttle on while adjust setting.
We take 2pcs new KLS4812S controller.
1 st test
1 st controller, 59 battery current, 37 phase current
The motor run when it’s cold, the max battery current is only 41.24A.
We have some KLS4812S controllers in store. And could do more test later.
1 st test
1 st controller, 59 battery current, 37 phase current
The motor run when it’s cold, the max battery current is only 41.24A.

Then we set 59 battery current, 45 phase current
The max battery current is 50.04A.

As former controller setting is supposed to be 59%-37%.
We tried the 2 nd controller.
2 nd controller, 59 battery current, 45 phase current
The max battery current is 51.34A

2 nd controller, 59 battery current, 43 phase current
The max battery current is 51.54A

2 nd controller, 59 battery current, 42 phase current
The max battery current is 51.89A

The max battery current is strange with the setting compare to former one and the 2pcs
controller with different settings.
After checking with Fany, he advise the % setting depends on internal resistance of mosfet. In
different environment temp, humidity, atmospheric pressure, the temp of controller, the setting
differs slightly.
The hardware and software of controller of different batch are the same.
So we go ahead for the 5min test with 59%-42%.
Before that, we warm up motor with 80% max RPM for 3min, the motor temp goes up to almost
120C.

Net power test in 5min.

Temp Rise Test
After that, we start temp rise test, not according to the rule of ECE R85.
As in ECE R85, the RPM should be above 90% peak power. In that condition, motor could not run
for 30min (the temp will go over 120C), so we have to limit the top speed to be 93% in controller
setting.
You mentioned need real continuous power of motor.
1 st temp rise test
In 43.2N.m, the motor go from 40.9C to 117.2C in 9min.
2 nd temp rise test
In 35.4N.m, the motor go from 46.2C to 125.7C in 30min.

During the test, we will try to find the balance power, I continue the test by decrease the torque,
The temp get down a little bit when it’s 30.7N.m to approx 117C.

3 rd temp rise test
In 30.7N.m, the motor go from 50.5C to 109.5C in 30min, and to 110.8C in 33min.
Peak Power and max torque Test
Due to my record, the peak torque of 205 35H V1 motor is 124.9N.m
100 phase current, 75 battery current,
The max battery current is 124.6A, peak power 2527W, peak torque 119.2N.m
The motor temp go up to 150C.

100 phase current,35 battery current,
The max battery current is 66.61A, peak power 2218W, peak torque 105.9N.m

Btw., during the test, we found the monitor page in the controller, there are phase current and
motor temp.
When the temp rise sharply, the motor temp is lagging.
When it goes up slowly, the motor temp is almost the same.

For phase current, it’s peak phase current, compare the measurement by tong-type ammeter, it’s
RMS phase current.
Conclusion
Setting
1.Suggest setting
59% phase current, 42% battery current
2.Temp Rise
30.7N.m, 1244W max continuous power at approx 110C
43.2N.m, 1634W for 9min
35.4N.m, 1416W max in 30min.
3.Peak Power of motor (full setting)
2527W
Peak Power of electric drive train