Varroc Engineering

About the Customer:

Varroc Engineering Limited is the second largest Indian auto component group, and a leading tier-1 manufacturer and supplier to Indian 2- & 3-wheeler OEMs.

The Company is focused on designing, manufacturing and supplying exterior lighting systems, plastic and polymer components, and electrical and electronics components. It also supplies precision metallic components to passenger cars, commercial vehicles, 2-wheelers, 3-wheelers, and off-highway vehicles (OHV). The Company’s segments include polymer, electrical, engine valve, forged components, and lighting. Its products include engine and engine parts, drive transmission and steering parts, suspension and braking parts, electrical parts, and other products including body and chassis.


Challenges and Solutions:

Varroc’s systems enable the mapping of performance parameters of their EV traction motors, types: (1) Hybrid Synchronous AC and Asynchronous AC Induction motors; (2) Synchronous BLDC and PMSM; and (3) ISG motors.

In addition, the systems could also (4) test the EV Traction Motor integrated with gearbox, i.e. having two O/P’s (similar to a Transaxle); and (5) are suitable for evaluating Hub Motors.

The systems were designed for evaluating multiple types and multiple manufacturers’ motors, with ranges of up to 25 kW, of up to 80 V, and max speeds of up to 15000 rpm.

The systems included Battery Simulation, with battery cycle testing (charge/discharge), battery SOC (State Of Charge) script and SOD (State Of Discharge) script, during advanced battery simulation and simple battery simulation, drive cycle testing (real-time simulation of scooter/driver, with acceleration, brake, change of vehicle states); and Battery Testing.

All advanced requested Motors Under Test are driven by their respective controller, with different types of communication protocols (CAN, LIN, A/D, FlexRay, Speedgoat, Modbus, etc.)


About the Product:

The MEA Regenerative Dynamometer System (MEA RDS) enables:

  • Complete load performance testing: Torque, Speed, Current, Efficiency, Input Power, Output Power.
  • Standard electrical parameters testing: HV, Vibration, Noise, and others.
  • Additional testing: Cogging, Back EMF, Friction, Friction Spectrum, Ripple Torque.
  • Automatic temperature rise test: Thermocouple device with 4 to 16 temperature channels, Current, Voltage, Speed, Torque, Input Power, Output Power, all synchronized to each temperature measurement.
  • Electrical Vehicle Motor Drive Cycle Load Simulation: Real-time simulation of scooter/driver, with acceleration, brake, change of vehicle states.
  • Battery Simulation: Battery cycle testing (Charge/Discharge), Battery SOC (State Of Charge) script and Battery SOD (State Of Discharge) script, during advanced battery simulation and simple battery simulation; Special feature: Low voltage dip at current transient; System includes Output Filter with high capacitance; Testing at U mode: Voltage Control (CV).
  • Battery Testing: I+ mode: Current Control (CC+); I- mode: Current Control (CC-); P mode: Power Control (CP), CC-CV, Step for cut-off condition (ET, EV, EC, CC time, CV time, Cap%, etc.), Protection (OV & LV, OC & LC, OT).
  • Additional EV Tests: Performance Generating mode & Performance Motoring mode, Stall Torque, Cogging Torque, Back EMF RMS, Open Circuit Back EMF, Back EMF Constant KE, No Load Coupled & Uncoupled, Torque Ripple Measurements at Low RPM & at High RPM, Electromechanical Time Constant, Voltage and Current Harmonics, Load from Excel File, Speed Torque Scope Viewer, Deceleration Test (MOI Calculation), Servo Bandwidth (Speed Loop & Current Loop), Dynamic Testing during acceleration and deceleration, Friction vs. Speed & Friction Drag Torque, Torque Speed FFT, Performance at Variable Voltage, Inductance Test 3 Phases, Vibration; ISG Tests: Generation Characteristic; ISO Efficiency Tests: ISO Efficiency and ISO Efficiency Contour; S1 to S8 – IEC duty cycles of operation for electrical motors.


Photos of the Customer’s system:



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