Position Sensor Simulation FS (RPS)

Analog output module for rotor position sensor simulation and electrical fault simulation

The Position Sensor Simulation FS (RPS) enables realistic generation of synchronous sine and cosine signals (GMR/AMR angle sensors) like those used by position sensors in electric machines. The system also allows targeted simulation of electrical fault patterns. The RPS platform is based on the NI sbRIO-9608 and, thanks to its modular structure and versatile communication interfaces (Ethernet & CAN-FD), offers a highly integrable solution for complex test environments.

Technical description

The RPS simulation unit has a modular design, and combining several groups provides a scalable number of channels. The position sensor simulation FS can be used to generate synchronous sine and cosine signals like those provided by position sensors in electric motors.

The simulation is available in several expansion levels. One module offers up to 30 analog outputs, making it possible to configure multiple output combinations. Another notable feature is the simulation of various fault patterns such as phase shift, amplitude and offset errors. Electrical faults such as short circuits and open lines can also be simulated. Thanks to calibration on delivery and their high reliability, the modules deliver very accurate long-term results. Recalibration in the IRS calibration laboratory is simple and maintenance-friendly.

Modular channel groups: Each group offers 5 analog outputs. The system is available in versions with 10, 20 or 30 channels.

• Dual mode: Synchronization of 2 channel groups at a time
• Communication & control:
• Ethernet: Full configuration and control
• CAN-FD: Full control, configuration via Ethernet required

Isolation: Each channel group is electrically isolated from the other groups, the system power supply and the housing.

Mechanics & housing options

The Position Sensor Simulation FS (RPS) is versatile – for both laboratory and production test environments.

19" integration: The modular hardware is prepared for integration into 6U 19" racks and can therefore be integrated seamlessly into existing test benches.

Benchtop housing: For development environments, manual test stations or research facilities, the RPS is also available in a rugged benchtop housing. This variant can optionally be powered with 230VAC.

Technical specifications

Ambient temperature

0 – 50 °C (non-condensing)

Supply voltage

23 – 25 V DC

Supply current at 24 V

typically 520 mA, max. 1 A

Number of channels

10, 20 or 30 (in groups of 5)

Sampling rate

1 MS/s

DA converter

16-bit resolution

Output voltage

0.01 – 5 V

Max. output current

15 mA

Short-circuit current

80 mA

DC accuracy

typically 0.1 %, max. 0.2 %

Output resistance

10 Ω

Rise/fall time

typically 0.6 µs, max. 1 µs (0 V to +5 V step)

Software

• LabVIEW .llb API and test panel
• C# API
• DBC file for CAN-FD control
• All relevant parameters configurable via software
• Open interface (JSON) for custom integration

Applications

Electric and hybrid vehicles, electric machines and other industrial applications: Optimization and validation of inverter solutions and control units through precise simulation of position signals in high-power environments, e.g. in drive systems, robotics and automation technology.

Design validation and end-of-line tests: Functional testing without original motors and sensors.

Research and development: The module enables efficient development and testing of inverter controls in a wide variety of applications, helping to increase the reliability and performance of power electronics.

With our Position Sensor Simulation FS (RPS), you create reproducible test conditions for a new generation of electrical systems.