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Fast Measurement of Voltage and Current Flows on E-Machines
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.
- vMeasure
Data acquisition software and online power calculation if required - HV Breakout Module (BM) 1.1 or 1.2
Single phase measurement of current and voltage - Inverter
The high basic frequency of e.g. 24 kHz requires a high time resolution of the measured values - Electric motor
Precise measurement results are the basis for performance calculation and efficiency determination - XCP-Gateway 4S pro
Synchronous acquisition of measurement data and conversion to the XCP-on-Ethernet protocol
Background
The synchronous and fast measurement of currents and voltages in all phases of an electric motor is the basis for the exact calculation of the electrical power or the determination of the efficiency. From the sampled values, the active, apparent and blind power is calculated with the eMobilityAnalyzer, a package which is included in the Vector software vMeasure or CANape.
Measurement task
Current and voltage measurement for power calculation.
Challenge
In this example, the voltages and currents of each phase of a three-phase synchronous motor with a rated power of 43 kW are to be measured. Different load situations are simulated in the test bench by varying the speed and the torque. The high basic frequency of the inverter of 24 kHz (41.6 µs) requires a time resolution of the measured values in the microsecond range in order to also record short voltage pulses at low load. The 480 V battery voltage used also requires special safety measures for the measurement modules.
The CSM Measurement Solution
- For current and voltage measurement, HV Breakout Modules (BM) 1.1 or 1.2 are inserted directly into the high-voltage cables. The modules measure currents and voltages directly synchronously and calculate the instantaneous power in real time if required. The measurement data can be output via the EtherCAT interface at a data rate of up to 1 MHz (1 µs).
- Via a XCP-Gateway 4S pro that synchronizes the measurement modules via Distributed Clock, the measurement data can be easily forwarded to common data acquisition software such as vMeasure. The XCP-Gateway converts the data acquired with EtherCAT into the common XCP-on-Ethernet standard.
Benefits
The HV Brekaout modules, with their high-voltage safe galvanically isolated inputs, ensure safety even at high voltages and meet the requirement for high time resolution of the measurement. With the synchronization of the measurement data and high measurement data rate, the current and voltage characteristics can be examined precisely. In this way, models created during development can be compared with the values actually measured and further optimizations can be made.
When using vMeasure, additional variables, e.g. power, can also be analyzed in real-time with the eMobilityAnalyzer.
More Information
Further Information
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CSM Xplained: Testing of fuel cell drives on test benches and in road testing
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CSM Xplained: Maintenance of HV measurement technology – calibration and insulation-test
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CSM Xplained: The Vector CSM E-Mobility Measurement System
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CSM Xplained: Voltage measurement in e-mobility
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CSM Xplained: Current measurement in e-mobility
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CSM Xplained: Autonomous power measurement in road tests and on test benches
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CSM Xplained: Measuring in high-voltage environments
Featured Products
Related Hardware
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 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.
The Vector CSM E-Mobility Measurement System
The measurement system for the development of electric mobility
HV Breakout Module 1.1
Single-phase measurement of internal conductor current and voltage
The HV Breakout Module (BM) type 1.1 has been specially designed for safe and precise single-phase measurement in single HV voltage power cables. Inner conductor current and voltage are measured directly and the instantaneous power is calculated in the module.
Related Software
vMeasure
Reliably Solving Complex Measurement Tasks
vMeasure, developed by Vector Informatik, is an easy-to-use software tool for the acquisition and analysis of measurement data that can be used in combination with all CAN- and EtherCAT®-based CSM measurement modules. CSMconfig was integrated directly to ensure swift configuration.
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.
