Testing and evaluation of Integrated Starter Generator system’s performance and durability characteristics in rig level using automation.

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. ISG system consists of 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 help of real sensors, actuators, and microcontroller to monitor and log the performance characteristics of ISG system during testing in rig level. Sensors continuously monitors the performance parameters and once the parameters not meeting the specification, actuators stop the testing and rise the indication. All tested data 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 vehicle and matched with actual customer field failures. From normal testing we can be able to find out actual failure modes and eliminating 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.