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High Torque SOP,

High Torque SOP

Make a Final TR

Implement deviations from the selected supplier RTS into requitements in SE-Tool. Make sure REQ states clearly deviations - so it is not confused later as "base req"

Supplier to confirm the Final TR

Collect in one Share point all relevant documents. Certifications, drawings, test data, data sheets...

Remove redundant and unnecessary documents.

New Shared Disk can be used - but is it safer than SharePoint? For ex. against accidental delete of info?

Discuss adding info about the contactors plating

Investigate all REQ for criticality level [SC, CC]

Add req about LV connector plating - align this with wire harness team.

Test and validation

R85 testing

Tune and calibrate EMD-F with selected motor (RIG testing!)

Book testing facility

Test can be made in AVL or Volvo trucks or even Penta. Witness is needed - contact Marcus Nyberg for more info if needed.

Sebastian is looking to book a place
-How to perform the test - load scenario, cycle, time etc.

Contacted VCA (Regulation authority)

CoP review for Vara

Audits needed to our test equipment and facilities (before summer break)

Check Penta rig28/29 with Dan J.
Cannot be used, Volvo Penta is not certified for this type of tests

Prepare for R85 test at GTT

Define test procedure in detail like:

pre-warming state

how to request the torque? Max from start and allow for derate or max achievable and let it be more constant?

Maybe test authority can support? or GTT?

Some points to look at:

ref torque matches measured

ensure we utilize all allowable EMD current

maximize torque output

Investigate possibility to use 509A as max peak current for EMD-F instead of 450 currently.

Any impact on warrantly?

Merge measured Flux map with simulated data - will that provide most optimum results?

Build a script to do the merging

Collect Flux data

Validate which map is better

Coordinate the test prequisites

Md Kashif -- Adapter Plate for the EM -- w44

Resolver Swap

EMC Test (25w24)

Prepare for EMC test

Plan for B2B test to be prepared for EMC test - Khaled

Run EM at speed control starting form 0rpm request up to 100%.

Check 0rpm in trq and spd control

Find out what DC power source can be used for the functional testing

Check if CAN and Visio logging works

Calibrate resolver offset

Check if flashing can be done with personal
laptop.

Install and test CANalyzer on personal laptop, to log data. Check if motor can be controlled

Check if Vision works outside of Volvo network

(ALC request, see Confluence https://confluence.srv.volvo.com/spaces/VPEMD/pages/536668973/Enable+ATI+Vision+connection+outside+Volvo+Network.)
Radek
13.01.2025 request for ACL sent
14.01.2025 - request approved
Vision works outside Volvo network

Get motors to the B2B lab

Rebuild LV Harness (adjust length of ISO pulses, correct pinout)
Radek?

Adjust cooling interfaces

Teflon tape

MasterTest.xlsx make a one file that will contain all the data

Get test plan from EMC team & review it. What and how to test.

Review together with EMC team the test scope if needed

Create a BOM for components (EM, EMD, LV/HV harness...)

List parameters of the components like:
DC voltage levels, max speed (for motor, not project), min, nominal and max cooling flow

Design place for logging the results

Work Order before test

LV harness - Khaled

Make extra set of 1.7m (+0.3, -0m) LV harness

LV harness with screen, without, GND on both and one end

Prepare in LV harness a bakeout for CAN & XCP

We want to log CAN data and be able to flash EMD

https://confluence.srv.volvo.com/spaces/VPEMD/pages/577465742/Modular+harness+MDS

Get Vocom2 adapter for EMD-F Flashing
https://confluence.srv.volvo.com/spaces/VPEMD/pages/592767634/Flashing+a+GTT+EMD

Confirm EM LV connector pinout for ABB (wrong one was delivered)

Make a CAN extension harness (with male & female on both ends

Make CAN portable termination (female - we have gender benders)

Get cooling connectors + teflon tape for sealing

HV harness - Khaled

Align with test lab required length and cable shoe size on their end.
Do they have EMC cable glands?

Make 1.5m of AC harness

Make DC harness

Length is going to be adjusted and crimped at RISE

Sent work order to the factory (Fredrik Aspling)

remember to bind the 3ph cables to prevent EMI

Get backup parts (EM, EMD, harness)

If EM/EMD needs to be backed up is dependent on the test scope. Potentially destructive tests might require it

make the grounding straps or wires to the test as well

Check with EMC Test Lab
Khaled

question sent to Zahra Sobhani 09.01.2025

Will HVIL signal be provided by the test lab?

What type of coolant is available? (Tap water, water/glycol?)

What water connections are in RISE? Can we bring connectors with us?

Water connections can be found in Tornado, RISE is using 19mm connection

Is power supply bidirectional?

What information Test Lab will require for the report?

What shall be DC cable length and interface toward power supply?

Check standards to define pass/fail criteria

Can they be incorporated into MasterTest.xlsx?

What should be reaction on "fail"?

Review the quote with EMC team, to confirm dates, working hours, location and responsibility division between Penta & Test lab

Ship all components to EMC Lab

Check EMC space in Confluence

Radek Checked and document filled in - still some missing info left.
https://confluence.srv.volvo.com/spaces/VPEMD/pages/569775089/EMC+WoW+MDS

Replace resolver (if ABB is selected)

Short HVIL pins in motor connector (no proximity switch implemented yet)

Use longer wire to simulate length of wires going to proximity switch.

Take to EMC test:

grounding cable - 2m (make it)

CAN case + cable for it

XCP split

Ethernet cable

VCOMM 2

HVIL resistor

LV harness

HV harness

DB9 gender bender (male & female)

cooling hose adaptors

Teflon tape

laptop charger

eye lugs for DC cables

Rent a car to go to test facility

Take ferrite filters

Extra cables for 24V supply

HVIL simulating resistors

Belt to secure the motor

arrange transport of the components

Durability tests - Kanelen?

Good to run durability tests on a vibration RIG, with climate abuse. Most likely out of budget scope - check with Resad

As drive cycle use modified 1000h cycle form diesel - available on the HT SharePoint

P-release testing
to collect data for data sheets and tune EMD, controller and flux maps (so that ref trq = real etc.)

Get thermal camera to observe HV harness temp

Apply chemical exposure according to RTS

KOLA releases

P-release

Needs to be investigated:

how process looks like

what data is needed (datasheet, drawings, TR?)

DONE

Spare Parts

Assembly Part

The process to finalize this is:

Take out partnumbers for the parts

Create cad models from the received models.

Reference to EM drawing or separate drawings if needed.

Add to assy part EM

Release models and (dawings)

AM to create instruktions based on received instruktions.

Parts list

Resolver

Terminal box cover

Terminal block for HV connection

Ventilation plugs

HV connector

LV Connector

Tech Data

Radek script

Torque only works, rest are buggy

Manual

Efficiency Data still to be done

Finalize SFMEA

Check actions from SFMEA and how they can be implemented.

*Probably not enough time & resource to do everything, but defining what needs to be done is always a first step.

Introduce Khaled to SFMEA work done so far

Review SFMEA - add that now EM shall be also used for propoulsion (it may change severities (failure effect) for example and preventative actions

Create manual

Both suppliers provided their manuals and installation guidelines.
P2901 manual can be used as a reference

Add information about storage conditions & need to rotate shaft every 6 months

Support CAE Team in creating EM and EMD Simscape model

Confirm MTPA data (i map generated by us matches the one from GTT scripts

Get absolutely basic IGBT parameters like Ron resistance. Check most basic model (except of ideal one) for more info

Validate if control is correct

Compare simulation with test data

Make MTPA calculations

Check with Marry if the results make sense and are useful.

Add voltage ellipse (to include BEMF impact and field weakening region)

EN 1175 testing
Khaled

4.10.4 Frame fault test - needs to be conducted. Tomek and Ali did it last time for EM3/4

make 3D printed cover for EMD

make 3D printed box for galvanically isolated switch

make a switch

4.10.3.2 Insulation resistance of truck
The insulation resistance between live parts

The REQ is on the truck level, so this make sense only when coordinated with other parts of the system. This is impossible now, so we can just ensure what is our insulation resistance value.

5.3.1 Electrical enclosures - confirm formally (SE-Tool, TR?) In principle fulfilled by both suppliers

4.10.1 Dielectric test (type test)

ABB and Parker are doing it on EoL. This test shouldn't be repeated too many times, due to stress put on insulation. I recommend to just confirm with selected supplier and get the EoL report (can be already on the Share Point)

Plan how to do it :D

Fredrik Aspling -- HV Harness -- w44

Take to R85 test:

[] grounding cable - 2m (we have)

[] CAN case + cable for it

[] XCP split

[] Ethernet cable

[] VCOMM 2

[] HVIL resistor

[] LV harness

[] HV harness

[] DB9 gender bender (male & female)

[] cooling hose adaptors

[] Teflon tape

[] laptop charger

[] Extra cables for 24V supply

[] Belt to secure the motor

[] arrange transport of the components

Rickard Udd (and Emin) -- LV Harness -- w43

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