Test Technologies Contributing to Electrification - 1. Test technologies that support the competitiveness of electric vehiclesFig. 5 Driving simulatorFig. 6 e-POWER powertrain bench test technologyFig. 7 Heat management system testThe first and most significant change in vehicle electrification is the replacement of the power source from an Internal Combustion Engine (ICE) to an electric motor. Electric motors generally offer superior responsiveness and finer control compared to ICE, thereby enhancing vehicle performance.In Battery Electric Vehicles (BEVs), the vehicle is powered by rotating the driving motor using the stored electrical energy in the battery.In Nissan's unique electric technology, e-POWER, a dedicated ICE drives the power generation motor to generate electricity, which in turn rotates the driving motor to move the vehicle.Both in BEVs and e-POWER, the range of performance control through electronic control is expanded, providing greater flexibility. With increased flexibility, there is a need to test with a greater variety of specifications in order to find optimal solutions. Attempting to accomplish this solely through physical tests using prototype vehicles would require significant time, effort, and cost for vehicle prototyping, modification (specification changes), and test evaluations. Therefore, applying virtual test technologies, as mentioned earlier, becomes essential.The following chapters will introduce driving simulator test technologies and e-POWER powertrain bench test technologies, which have been developed against this backdrop.Compared to Internal Combustion Engine (ICE) vehicles, customers place a higher emphasis on the driving range when it comes to Battery Electric Vehicles (BEVs). The driving range of a BEV is determined by battery capacity and energy efficiency. Among the factors affecting energy efficiency, aerodynamic resistance has the most significant impact. As a means of reducing aerodynamic resistance, the adoption of electrically retractable door handles is becoming more prevalent. Even with the movement of such electric components, setting appropriate targets allows us to provide customers with emotional values such as a sense of luxury and advancement. In this regard, utilizing virtual technology is more efficient and effective than repeating trial and error with various prototype specifications. This is exemplified in Chapter 4, which introduces virtual reality test technologies.With electrification, new challenges arise regarding heat balance. BEVs have high efficiency as they lack the waste heat energy generated by ICE, but this also means that interior heating utilizing waste heat is no longer possible. Furthermore, cooling is required during high-load driving and quick charging to maintain the battery and motor at optimal temperatures, and this cooling system is shared with the interior air conditioning system. Achieving an efficient thermal management system necessitates a vast number of test evaluations based on different combinations of driving, charging scenarios, and ambient the increasing complexity of the system.To address this, Chapter 5 presents the thermal management system test technologies that have been developed. The last technology to be introduced is X-ray CT non-destructive measurement technology. The demand for non-destructive measurement is increasing in areas such as the development of electric vehicle-specific components and systems like batteries and motors, as well as the adoption of new materials and methods for vehicle lightweighting. By having this technology in-house, Nissan is able to respond quickly to these needs.What all these technologies have in common is that temperatures, given 36
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