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Application Examples

You will find application examples (Use Case) for the application of CAN and EtherCAT measurement technology as well as data loggers here.

Downloads: 47


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.
Version 1.1.1
Download Language English
Size 426.67 KB

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.
Version 2.2.0
Download Language English
Size 350.48 KB

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.
Version 1.2.0
Download Language English
Size 1.13 MB

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.
Version 1.2.0
Download Language English
Size 1.82 MB

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.
Version 3.2.1
Download Language English
Size 534.25 KB

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.
Version 1.1.0
Download Language English
Size 1.19 MB

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.
Version 1.3.1
Download Language English
Size 282.65 KB

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.
Version 2.0.0
Download Language English
Size 496.15 KB

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.
Version 1.1.0
Download Language English
Size 424.56 KB

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.
Version 1.2.0
Download Language English
Size 433.43 KB

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.
Version 1.2.0
Download Language English
Size 451.35 KB

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.
Version 1.1.0
Download Language English
Size 698.67 KB

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.
Version 1.1.0
Download Language English
Size 761.22 KB

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.
Version 2.1.1
Download Language English
Size 720.62 KB

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.
Version 1.2.0
Download Language English
Size 381.31 KB

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.
Version 1.2.2
Download Language English
Size 476.98 KB

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.
Version 2.0.0
Download Language English
Size 312.55 KB

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.
Version 3.3.1
Download Language English
Size 632.79 KB

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.
Version 1.2.1
Download Language English
Size 382.9 KB

Version 1.1.1
Download Language English
Size 432.3 KB

Version 2.2.0
Download Language English
Size 352.67 KB

Version 1.2.0
Download Language English
Size 1.82 MB

Version 1.2.0
Download Language English
Size 1.13 MB

Version 3.2.1
Download Language English
Size 533.35 KB

Version 1.1.0
Download Language English
Size 1.2 MB

Version 1.3.1
Download Language English
Size 280.03 KB

Version 1.1.0
Download Language English
Size 424.04 KB

Version 2.0.0
Download Language English
Size 529.17 KB

Version 1.2.0
Download Language English
Size 449.42 KB

Version 1.2.0
Download Language English
Size 428.92 KB

Version 1.1.0
Download Language English
Size 818.56 KB

Version 2.1.1
Download Language English
Size 761.87 KB

Version 1.2.2
Download Language English
Size 469.95 KB

Version 2.0.0
Download Language English
Size 313.95 KB

Version 1.2.0
Download Language English
Size 379.51 KB

Version 3.3.1
Download Language English
Size 605.02 KB

Version 1.2.1
Download Language English
Size 394.49 KB

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.
Version 2.0.1
Download Language English
Size 713.54 KB

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.
Version 2.0.1
Download Language English
Size 727.48 KB

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.
Version 1.0.0
Download Language English
Size 513.4 KB

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.
Version 1.0.0
Download Language English
Size 498.45 KB

Within the high-voltage components of electric vehicles, the currents and voltages must be measured at high frequency and with high accuracy for testing, validation and verification. However, the installation space for the necessary measurement technology directly into integrated e-axles, inverters or high-voltage batteries is extremely limited. The following application example shows how CSM’s innovative measurement technology simplifies the instrumentation on busbars.
Version 1.0.0
Download Language English
Size 484.72 KB

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.
Version 1.0.0
Download Language English
Size 309.94 KB

Version 1.0.0
Download Language English
Size 309.52 KB

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.
Version 1.0.0
Download Language English
Size 3.55 MB

Version 1.0.0
Download Language English
Size 3.78 MB