Load emulator: innovative testing technology for the repair of large converters, inverters, cabines

Emulation describes the ability of a system to realistically replicate the behaviour and functions of another system. This makes it possible to simulate operating systems, software or hardware with such precision that no original component is required for troubleshooting. 

At EICHLER, a load emulator is used that accurately simulates a three-phase asynchronous motor. With the help of modern FPGA technologies, frequency converters or inverters can interpret the emulator's signals as if they were coming from a real motor, enabling testing without any physical hardware. 

Key features: 

• Configurable dynamic and load scenarios for frequency converters and inverters from various manufacturers (e.g. Siemens, Lenze, Danfoss, SEW, ABB, etc.)
• Maximum testing depth thanks to the electronic replication of real machine loads
• Warranty extension of up to 36 months
• Test report including all relevant test results

The innovative testing technology integrates seamlessly into the proven EICHLER repair process. Following the technical cleaning - precisely tailored to each assembly and carried out using state-of-the-art methods - the repair is performed. The devices are then thoroughly tested under realistic load conditions using the load emulator. Customers benefit not only from a warranty extension of up to 36 months and a detailed test report, but also from the assurance that only devices which operate flawlessly under continuous load are returned to them. 

Test highlights: 

• Endurance test of at least 90 minutes under realistic operating conditions
• Speed-controlled or positioning drive emulation including resolver feedback
• Automated test procedures for maximum quality assurance
• Detailed test report including all relevant measurement values

Load emulation is particularly valuable when it comes to high-performance testing. At the heart of the EICHLER load emulator is a galvanically isolated, bidirectional 100 kVA emulation and testing system equipped with several independent power amplifiers. 

Unlike conventional motor test benches, the power and energy of the emulated motor are not converted into heat. Instead, the energy remains within the emulator and is cyclically fed back into the overall system. This makes the testing process significantly more efficient, more sustainable and more realistic. 

The following illustration shows the difference between a traditional test bench with motor and brake, and the modern test setup with a machine emulator, in which the load energy circulates. 

This creates an energy cycle that supports the sustainability principles of Eichler GmbH and WISAG - an energy loop within the overall system with only very low power losses from the supply grid. Measurements show that an emulated 100 kVA machine results in only 10% grid load. 

With the load emulator, EICHLER is setting new standards in the repair and testing of large converters. The combination of realistic emulation, automated test procedures and sustainable energy utilisation ensures maximum quality, efficiency and long-term reliability in maintenance.