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High-voltage Measurement Technology and NVH in Mobile Testing
In addition to changes in current, voltage and power measurements, electric powertrains also bring new challenges for acoustics: The HV electrical system and its assemblies, new materials and the elimination of masking noise sources require a holistic view of acoustics and performance parameters. This application example shows how a harmonized measurement system can be used to acquire and analyze the necessary measured values.
Background
Engineering and testing of electric powertrains are subject to new requirements. New components, technologies and materials also lead to new acoustic and vibration-related issues.
The development of new, high-performance electric vehicles requires innovative, holistic engineering and testing. For the development, a measurement system is needed that provides both e-mobility analyses and NVH analyses.
Measurement Task
Acquisition of acoustic signals and current, voltage as well as power for a holistic analysis of the electric powertrain.
Challenge
For a holistic analysis and targeted optimization of the electric powertrain, signals for NVH analyses and measured values for performance analyses must be acquired synchronously and bundled in an analysis software.
The synchronous acquisition of all required values saves valuable time, as no time-consuming manual post-processing of the data is necessary. This requires a measurement system that can process the large amount of raw data in real time.
The measurement technology used must be compact and robust so that it can be installed directly in the vehicle, close to the measurement point. This means that the same measurement technology can be used on the test bench and in the road test, and that the test results can be compared. In addition, HV safety for systems and users must be ensured.
The CSM Measurement Solution
With a harmonized measurement system consisting of hardware and software from Müller-BBM VibroAkustik Systeme, which is supplemented by hardware from CSM, all necessary measured values can be acquired synchronously and analyzed in real time.
- A microphone array multimic from Müller-BBM VAS is installed for the acquisition of the acoustic signals. This allows an exact and repeatable arrangement of the microphone positions.
- The sensors of the multimic used for vibroacoustic measurements are directly connected to measurement modules AD4 IE100.
- In the HV electrical system, currents and voltages are measured directly in the HV power cables between the components with the HV Breakout Module 1.2 and the HV Breakout Module 3.3.
- In addition, temperatures in the HV battery, inverter and electric motor can be measured with the temperature measurement module HV TH4 evo.
- All measurement modules are connected to a XCP-Gateway via EtherCAT® and synchronized better than 1 μs.
- The CSM PAK AddOn connects the measurement chain to the Müller-BBM VAS PAK live.hub. All CSM measurement modules continuously send the data stream to the PAK live.hub, which dynamically redistributes the data stream as a data hub.
- Via the PAK live.hub, the PTP synchronous data stream is provided in real time to the PAK NVH software suite PAK 6.X.
- With PAK 6.X, all necessary analyses (e.g. electrical and mechanical power, d/q transformation and modulation analysis) as well as evaluations in the areas of structure, rotation and sound quality are performed in real time.
Benefits
Due to the simple networking of the data streams, a wide variety of test tasks can be comprehensively solved with one measurement system. Due to the compact measurement technology, acoustic and performance-related phenomena can be validated in the vehicle.
The high data rates and ensuring the synchronicity of all connected measurement modules allows the analysis in real time.
More information
Further Information
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CSM Xplained: Current measurement in e-mobility
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CSM Xplained: Voltage measurement in e-mobility
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CSM Xplained: Acceleration measurement in e-mobility
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CSM Xplained: Durability measurement in e-mobility
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CSM Xplained: Maintenance of HV measurement technology – calibration and insulation-test
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CSM Xplained: High-voltage- and NVH-Measurements in Electric Vehicles
Related Products
Related Hardware
HV Breakout Modules 1.2, 1.2C
Single-phase measurement of internal conductor current and voltage
The HV Breakout Modules (BM) Type 1.2 have been specially designed for safe and precise single-phase measurement in separated HV+ and HV- power cables. Inner conductor current and voltage are measured directly and the instantaneous power is calculated in the module.
XCP-Gateway
The protocol converter for EtherCAT® and CAN to XCP-on-Ethernet
XCP-Gateway is the interface between the data acquisition software (e. g. vMeasure, CANape®, INCA®, Vision® ...) and the EtherCAT® measurement modules from CSM. It includes an EtherCAT® master and an XCP-on-Ethernet slave.
HV Breakout Modules 3.3, 3.3C
Three-phase measurement of internal conductor current and voltage with direct XCP-on-Ethernet output
The HV Breakout Modules (BM) Type 3.3 have been specially designed for safe and precise three-phase measurement in HV power cables. The inner conductor currents and outer conductor voltages are directly acquired and output via XCP-on-Ethernet.
HV TH Measurement Modules
Safe temperature measurement with K-type thermocouples
Safe temperature measurements with thermocouples on high-voltage components: the high-voltage-safe temperature measurement modules are specifically designed for the reliable acquisition of temperatures in electric and hybrid vehicles.
Related Software
CSM PAK AddOn
For simple integration of our measurement modules into a Müller-BBM measurement setup, we have developed the CSM PAK AddOn. With this software extension, measurement data from CSM measurement modules can be synchronously transferred to the PAK software from Müller-BBM and examined there together with other measurement data (requires the PTP/IEEE1588 option for the CSM measurement module or XCP-Gateway providing data via XCP-on-Ethernet).
Swift configuration of measurement chains: CSMconfig is the reliable configuration software for all CAN and EtherCAT® based measurement modules from CSM. The clearly arranged and easy-to-use user interface allows an easy setting of all measurement parameters. This helps speeding up the measurement setup considerably.
