Emulator for a DC-Machine, working as an actuator in a torque split unit of an all-wheel driven automobile

The aim of the constructed emulator system, in association with a mathematical simulation model of an actuator running on a digital-signal-processor-HIL system (Hardware-in-the-Loop system) is to replace a real actuator and its positioning sensors. The emulator is the physical link between the real actuator supply electronics and the mathematical actuator model. From the (electrical) view of the power supply or power electronics controlling an actuator it makes no difference whether a real actuator or the emulation system is connected. This enables actuator system designers to quickly change drive parameters and check their effects on control electronics to speed up electronics and actuator design processes. Another possibility is to check control electronics under special actuator conditions which may result in destroying a real actuator. The main part of the emulator is a controllable voltage source in order to emulate the inducted armature voltage of the actuator. This electronic source and load unit consists of two pulse width modulation amplifiers working as buck converters. The armature resistance and inductance are emulated by physical parts. Furthermore, the position signals generated by the signal-processor-HIL system are electrically isolated and used for emulating the position sensor signals.