High-Voltage Current and Voltage Measurement

Current and Voltage Measurement in High-Voltage Busbars

To save valuable space, components in the electric power train are becoming more compact and integrated. At the same time, this limits the space for installing measurement technology needed for current and voltage measurements in the busbars of integrated e-axles, inverters or HV batteries. Precise measurement results for testing, validation and verification are thus difficult to achieve. This example shows how high-frequency measurements can be carried out in busbars despite the confined space available.

Current and voltage measurements in the HV environment: testing both performance and safety

During the development and validation of electric vehicles, a series of tests must be carried out in the high-voltage environment. HV-safe measurements of currents and voltages must not only be made from the perspective of a power calculation, but also to rule out hazards from potentials applied to the vehicle. Measurement modules that can carry out several voltage and current measurements simultaneously and process data directly are therefore ideal for the efficient execution of many measurements.

Fuel Cell-electric Drive Functional Test

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-Voltage Current and Voltage Measurement in Confined Spaces

In the high-voltage electrical system of electric vehicles, high-frequency currents and voltages are measured during test drives. The space required for installing the necessary measurement technology can be very limited due to tightly installed components and cable ducts. This application example shows how currents and voltages can nevertheless be measured with high sampling rates, HV-safe and protected from environmental influences.

High-Voltage Safe Measurements at Charging Stations

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.

Measuring Shield Current of High-Voltage Cables in Electric Vehicles

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.

Testing Charging Processes - Increasing Acceptance of Electric Vehicles

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 from CSM was used for this purpose.

Verification of High-Voltage Electrical Systems

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.