Testing and Evaluation of Integrated Starter Generator System’s Performance and Durability Characteristics in Rig Level Using Automation

<div class="section abstract"><div class="htmlview paragraph">Automobiles are incorporated with advanced technologies to improve riding experience, safety, and vehicle management. Considering riding experience, major concern prevails in starting and charging system. For quick start and stop, implemented Integrated Starter Generator (ISG) in two wheelers. The ISG system consists of an ISG machine and ISG controller. ISG machine acts as motor during cranking and generator during charging, controlled by ISG controller. Automation kit is made with the help of real sensors, actuators, and microcontroller to monitor and log the performance characteristics of ISG system during te sting in rig level. Sensors continuously monitor the performance parameters and once the parameters are not meeting the specification, actuators stop the testing and raise the indication. All tested data are stored in cloud and taken for analysis. This automation kit served two purposes. One is eliminated test running on the failure sample for full long testing duration. Second is from logged data, failure conditions with respect to output, speed of ISG machine, Coil temperature, controller temperature, actual torque vs speed characteristics is derived. These conditions are simulated in vehicles and matched with actual customer field failures. From normal testing we can be able to find out actual failure modes and eliminate many trails for simulation. Performance deterioration can be analyzed from logged data through data analytics tool. This paper addresses the automation test setup readiness to monitor and log performance characteristics during testing, findings of simulating conditions by data analytics, testing the findings in actual vehicle, and solving the failure mode through detailed problem-solving techniques.</div></div>