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Efficiency Measurement of a High-Voltage Powertrain Download

Electric powertrains have to be tested during many development phases. The overall efficiency is an important parameter for further optimization. In this application example, you can learn how the overall efficiency of fully integrated electrical powertrains is calculated in real time.

Experimental Stress Analysis on Crane Booms Download

Mechanical stresses and their direction must be determined for the structural design of many components with experimental stress analyses. The exact knowledge of the structural load-bearing capacity is particularly relevant for the development of components on construction machines that are later subjected to heavy loads. This application report shows how CSM measurement modules accurately measure stress at numerous locations during repeatable experimental stress analysis on telescopic crane booms.

Formula E case study Download

Motorsport places the toughest demands on man and machine; and also on the measurement technology that is indispensable for development. ABT Sportsline, together with Audi and Schaeffler, has used CSM's measurement technology in Formula E to obtain precise data during the development and testing of the racing cars. Find out in the following application report where CSM measurement technology was used.

Fast Measurement of Voltage and Current Flows on E-Machines Download

During the development of the electric power train for electric vehicles, voltage and current characteristics at the AC phases of the electric motors must be recorded and analyzed. The HV Breakout Modules are particularly suitable for this purpose, as they measure required values extremely quickly, synchronously and precisely.

Fuel Cell-Electric Drive Functional Test Download

Fuel cell-powered vehicles are a complement to pure battery electric-powered vehicles in electromobility. An electrochemical reactor is used to generate electrical energy that is available for the drive and other vehicle systems. The interaction of this reactor in the fuel cell stack with the other components in the powertrain is tested on test benches. In this example, you will learn how the necessary measurements are carried out simply and synchronously.

High-Speed Power Measurement on an E-Scooter Download

The range of electric vehicles determines their suitability for everyday use and acceptance by users. For a steady increase in range, the electric power trains and their components must be continuously optimized. The following example shows how an efficient power measurement in the low-voltage range is carried out. Similarly, such a measurement could also be made in the HV range.

High-Voltage Safe Measurements at Charging Stations Download

The everyday use and acceptance of electric vehicles depends on the widespread availability of charging facilities. Various charging concepts are required for the expansion of the charging infrastructure and are being tested in detail by the operators of charging station networks. High-voltage safe current and voltage measurements must be carried out at many points. The following example shows how this can be done.

Investigation of the Thermal Runaway in Vehicle Batteries Download

Thermal runaways in the HV batteries of electric and hybrid vehicles can lead to fires that are difficult to extinguish and endanger passenger safety. Extensive testing is required to ensure that HV batteries are designed safely with suitable protective mechanisms. In this application example you will learn how the necessary temperature measurements can be carried out at many points in the battery.

High-Voltage Safe Strain Measurement in HV Batteries Download

The housings of HV batteries not only serve to protect the battery cells and electronics inside them, but are also a structural part of the vehicle frame. Mechanical loads must be measured for an optimal housing design - inside and on the outside of the housing. This example shows how the necessary measurements are made easily and safely with strain gauges and strain gauges measurement modules.

Measurement Technology for the Analysis of Highly Dynamic Currents Download

To keep down fuel consumption rates, the fuel supply system must be regulated to match the fuel demand. Current flows at the electronic control unit (ECU) for the fuel pump are recorded over an extended period of time to find out whether its fuse is correctly rated or not.

Measurement Technology for the Analysis of Electrified Engines Download

To optimize efficiency and driving comfort, a German car manufacturer focuses on electrified gasoline engines. Key component of this technology is the integrated starter generator (ISG). For its best possible application, fast current and voltage measurements are indispensable.

Measuring Shield Current of High-Voltage Cables in Electric Vehicles Download

The development of high-performance electric passenger cars, commercial vehicles, buses or mobile machines poses extraordinary challenges due to a particularly large high-voltage vehicle electrical system. High shield currents can destroy the cables and must be measured.

Powertrain Validation in Forklifts Download

Validation testing is often needed when extensive design updates are made to the vehicle system. In these cases, all important vehicle parameters are tested under a wide range of operating conditions. The following example shows how such tests are performed on forklifts that incorporated new engine options.

Real-time Efficiency Measurement on Inverter and Electric Motor Download

The optimal design of inverters is necessary for increasing the range per charge and performance of electric vehicles. The inverter is the link between the battery and the electric motor and plays an important part in the electric powertrain. This application example shows how power and efficiency calculations are performed on the inverter and how the measurement setup can easily be expanded for further measurements.

Safe Drop Test Measurements for HV Electric Vehicle Batteries Download

This example shows how accelerations inside and outside a high-voltage battery pack are measured during a drop test to verify vehicle safety. CSM measurement technology offers a simple solution because a subsystem with both high- and low-voltage components can be measured synchronously with a single measurement system utilizing high sampling and data rates.

Safe Temperature Measurement in High-Voltage Batteries Download

High-voltage batteries play a central role in the development of electric vehicles. Temperature management is one of the key factors for their optimal function, which is why temperature measurements are carried out under different conditions during development and pre-series production. This example shows how such a temperature measurement can be realized in the high-voltage battery.

Thermal Charakterisation of HV Batteries Download

The thermal characterization of high-voltage batteries requires precise temperature measurements down to cell level with a large number of sensors. Only with precise insights in the thermal behaviour of battery cells and the whole system further optimization can be performed. With the HV DTemp measurement system, temperatures on the cell level can be measured with up to 512 sensors on only one sensor cable.

Verification of High-Voltage Electrical Systems Download

The high-voltage electrical system in electric and hybrid vehicles is validated at all stages of development and extensively tested for series production release. CSM HV Breakout Modules are particularly suitable for these validation and acceptance measurements in accordance with the ISO 21498-1 and -2 standard because they can be used directly in the HV cables of the vehicle electrical system.

WLTP Power Measurement of Electric and Hybrid Vehicles Download

In the European Union, consumption values for new passenger cars and light commercial vehicles must be measured for type approval according to the WLTP (Worldwide Harmonized Light-Duty Vehicles Test Procedure). This also applies to electric vehicles (battery electric vehicles and hybrid electric vehicles), for which the electric range is also determined. This example shows how the electrical energy consumed and the range per charge can be determined according to the WLTP.

Power and efficiency analysis of an electric powertrain Download

High performance cars and heavy duty trucks often utilize multiple electric motors. This architecture results in the power and performance tests on test benches to be particularly challenging. Even early in the development process the individual components and their interactions are tested with real-time simulations of actual driving maneuvers on test benches and the performance parameters are verified. For this purpose, the power and efficiencies of the components are analyzed in real time and the raw data is recorded.

High-Voltage Current and Voltage Measurement in Confined Spaces Download

For tests drives of electric vehicles, high-frequency currents and voltages must be measured in the high-voltage vehicle electrical system. The installation options for the necessary measurement equipment can be very limited due to confined installation spaces. This application example shows how currents and voltages can nevertheless be measured with high sampling rates, HV-safe and protected from environmental influences.

Fatigue strength measurement on tie rod and axle control arms Download

The optimization of hybrid and electric vehicles not only extends to the popular topics of body and the electric powertrain engineering, but obviously includes all components of the vehicle. Weight must be saved in some areas to offset increases in others, such as the entire battery pack, as a way to achieve maximum performance and energy efficiency. But the components must also be permanently stable and reliable. For this reason, chassis components are also optimized in terms of weight and durability. This example shows how fatigue strength measurements are carried out on tie rods and axle control arms.

High-voltage Measurement Technology and NVH in Mobile Testing Download

Electrifi cation of the vehicle powertrain poses major challenges for the interaction of the individual components. Influencing factors include the high-voltage electrical system and its connected assemblies, new materials and the elimination of masking noise sources. With synchronous acquisition of NVH and powertrain performance data, it is possible to take a holistic view of development issues and efficiently address conflicting goals between acoustics and performance.

Measurements of the mechanical load of a solar-powered passenger car test vehicle Download

Along with the shift from combustion engine drives to electromobility, the question arises of where the electricity will come from to run e-motors in vehicles in the future. One idea: solar panels integrated into the vehicle to charge the battery. For this purpose, a fleet of solar-powered test vehicles has been developed as part of Sono Motors' Sion program. One of these accompanied CSM in the integration of the necessary measurement technology for acquiring the mechanical loads and the electrical power of the powertrain.

Real-life Fleet Testing Download

During a fleet test of electric vehicles in Asia, very high ambient temperatures of more than +50°C were encountered. For the analysis of the interior temperatures in interaction with the electric drive and the battery, the measurement results had to be reliably recorded despite the high load for the measurement technology used. With the UniCAN 3 data logger from CSM, the test could be carried out even during a heat wave without loss of function or interruptions.

Measurement of Wheel Force for Durability Download

At the EVZ, the development and testing center at Daimler Truck in Wörth (Germany), new trucks are being developed to production readiness. Twelve years ago, the decision was made to measure the forces interacting between ground and wheel with wheel force transducers, and three years ago the Kistler KiRoad Performance system was introduced. During the testdrive, the forces and torques acting on the rotating wheel in the X-, Y- and Z-axes are precisely measured and acquired. At the same time, measurements are carried out with CSM measurement technology on up to 200 analog channels in order to be able to analyze the mechanical loads in the components. With the KiRoad Performance Gateway developed by CSM, the measurement data from the various systems can be synchronously acquired and evaluated.

Testing Charging Processes Download

Being able to charge e-vehicles worldwide is an important goal in the development and improvement of components involved in charging processes. National differences in power grids as well as individual characteristics of the charging devices are the main challenges. During the prototype development of a new e-car with a modified on-board charger (OBC), international charging processes and their repercussions on the power grids had to be investigated in detail using measurement technology. In particular, the HV Breakout Module (HV BM) 3.1 OBC was used for this purpose.

How does comfort in the vehicle influences range? Download

Offering long ranges for electric cars is one of the biggest challenges for vehicle manufacturers. The decisive factor here is the total energy consumption of the vehicle. Often, only the consumption of the electric powertrain is considered, but: How much does the low-voltage vehicle electrical system, which includes driver assistance systems and infotainment, contribute to discharging the drive battery? For competitive analyses, the currents of these components were therefore examined in more detail: Around 100 CSMshunts of different variants were used for benchmarking an e-SUV.