We support our customers with innovative measurement solutions for product development. Our measurement technology is used in many areas and at all stages of development. Especially in the area of high-voltage safe measurement technology, we were able to develop new solutions together with our customers. In the following we present a selection of possible applications of CSM measurement systems.
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.
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. The following example shows how such a temperature measurement can be realized in the high-voltage battery.
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.
The high-voltage cables of the high-voltage vehicle electrical systems in modern electric vehicles are exposed to strong current and voltage ripples, which induce currents in the braided shields. If these shield currents exceed the capacity of the braided shield, cable fires and damage to connected accessories are the result. To ensure the safety of the system, extensive measurements of the shield currents are necessary.
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 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.
New tests for electric vehicles and their components are intended to ensure the safety of passengers and systems and are a basic requirement for approval on various markets. One example is a drop test for high-voltage batteries, which is mandatory for verification for the Korean market. The following example shows how the necessary acceleration measurements inside and outside the high-voltage battery are performed during the drop test.
In order to further optimize efficiency and driving comfort, automobile manufacturers are using integrated starter generators (ISG) in mild hybrid vehicles. Fast current and voltage measurements are crucial for the optimal application of this technology. CSM offers the suitable measurement technology to perform measurements with high data rate and also in mobile testing.
To further minimize fuel consumption, the fuel supply must also be regulated according to demand. The recording of current curves on the fuel pump control unit over a long period of time is intended to verify whether its fuse is correctly dimensioned. In the following application report you will learn how such a measurement can be carried out easily and how the advantages of CAN and EtherCAT-based measurement modules can be combined.
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.
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.
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.