The control hardware is comprised of Opal-RT engineered components and some standard computer components (such as Intel processors) to achieve very high-speed and precision real-time simulation.

The DriveLab kit includes the external power supply, the interface cables, and the real-time simulator.

The real-time simulator components can be divided into two categories:

For the DriveLab kit application, we will focus on the I/O interface.

Real-Time Simulator I/O

Analog Inputs

Opal-RT’s standard analog input range is +/-20V. The DriveLab application scales the voltages in order to comply with this specification. The analog input carrier connector on the real-time simulator is known as a DB37F connector (see I/O Cables for details).

In this configuration, analog inputs are used to read the phase currents and the DC bus voltage.

• Currents A1 and B1 of inverter circuit #1
• Currents A2 and B2 of inverter circuit #2
• +36V common DC bus voltage

Digital Inputs

Opal-RT digital inputs are opto-isolated.

In this configuration, digital inputs are used to read encoder feedback provided by the DriveLab box and the encoders:

• Fault detection on inverter circuit #1
• Fault detection on inverter circuit #2
• Encoder feedback (A, B, Z) from both encoders
• Hall effects (U1, V1, W1) of encoder 1 (8-pin)

Opal-RT digital outputs are opto-isolated and require an external DC voltage source as a voltage reference level for the digital signals to be outputted. In the DriveLab application, this voltage is fed by the DriveLab box to the real-time simulator.

In this configuration, digital outputs are used to provide signals to the DriveLab box:

• Firing of phase A1, B1 & C1 (PWMs) on inverter circuit #1
• Firing of phase A2, B2 & C2 (PWMs) on inverter circuit #2
• Fault clearance signal (common to both circuits)

I/O Cables

Real-time simulator inputs and outputs must be properly connected to the DriveLab box to interact with it.

OPAL-RT provides two custom cables to connect both systems; each cable has two different connectors at either end:

113-0371 ANALOG INPUT CABLE

• Standard DB37M connector (to connect to the simulator analog I/O slot)
• 50-pin connector (to connect to the DriveLab box analog inputs connector)

Refer to Pin assignments for the analog input DB37 pin description and for the 50-pin analog input connector pin description.

External Power Supply

The external power supply provided with the system is used to power the DriveLab box, which requires an external +36VDC source to power the common DC bus. Although the power supply provided may be able to reach higher voltages, it must be set to +36VDC. Higher voltages may result in damage to the DriveLab box and to other hardware components.