Multi-channel Power Analyzer Test Solution for New Energy EV Motor Drive System

Industry Background and Technical Challenges

As the global penetration rate of new energy vehicles exceeds 35% (according to IEA data in 2025), electric drive system testing faces three core challenges:

1. High dynamic response requirements: Transient switching of motor speed 0-15000rpm requires millisecond-level data capture.

2. Complex energy efficiency evaluation: System efficiency under 800V high-voltage platform needs to be accurate to ±0.1%.

3. Multi-physics field coupling: Need to synchronously correlate electric power data with mechanical parameters such as temperature/vibration.

Core Test Requirements

‌Synchronous multi-channel measurement‌: It is necessary to simultaneously collect high-precision synchronous data of motor controller input power (DC), motor output power (AC), and mechanical power (torque/speed), and calculate system-level efficiency (such as the product of inverter efficiency η₁ and motor efficiency η₂).  So, a high precision multi-channel power analyzer is necessary to achieve this.

‌Dynamic working condition verification‌: Covering power flow analysis of transient processes such as acceleration and energy recovery, verifying the symmetry of bidirectional operation efficiency‌.

‌Complex system adaptation‌: Supporting real-time linkage testing of front and rear axle power of dual-motor four-wheel drive system to avoid data splicing errors of multiple devices‌.

Key Technical Solutions

1. Hardware configuration requirements

Channel expansion capability: at least 6 power channels (such as DC bus + dual three-phase motors), supporting power above 250kW and 500A current sensors;

Accuracy indicators: basic voltage/current accuracy ≤ 0.05%, frequency bandwidth ≥ 500kHz (such as German GMCI LMG671 series);

Synchronous sampling: all channels use a unified time base, sampling rate ≥ 1MS/s, to ensure accurate capture of phase difference.

2. Key parameter measurement matrix

3. Typical test scenarios

4. Software analysis function

Efficiency MAP diagram generation: Draw the motor's efficient working range based on the torque-speed curve;

Loss quantification analysis: Separate power loss components such as iron loss and copper loss to locate energy efficiency bottlenecks;

Durability test: Continuously record charge and discharge cycle data and support semi-automatic long-term operation verification.

Industry Application Value

R&D optimization: Shorten the verification cycle of power electronics topology innovation by more than 50%;

Production line detection: A single device replaces multiple instrument stacks to reduce testing costs by 30%;

Standard compliance: Meet ISO 7637 electromagnetic compatibility and GB/T 18488 motor test specifications.