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.
The high-voltage vehicle electrical system in modern electric vehicles connects various consumer systems with the high-voltage battery. Connected inverters and converters cause retroactive current and voltage ripples in the high-voltage DC circuits, which can cause damage to components. For this reason, vehicle manufacturers test and verify the high-voltage vehicle electrical system quality in order to ensure the operation of all consumers with all functions over the entire vehicle life cycle. Their own in-house standards and the ISO 21498 (consisting of part 1 and 2) standard will serve as a guideline.
Precise measurement of current and voltage curves in the entire HV vehicle electrical system to prevent damage caused by current and voltage ripples.
The high-voltage vehicle electrical system must be checked during driving, since critical driving situations can only be inadequately represented on the test bench. In addition, voltage and current characteristics must be measured particularly quickly and precisely in order to detect even short-term voltage peaks. Direct effects of driving situations can only be truly evaluated by real-time analysis of all measurement signals using data from the ECU and intelligent triggers. To do this, all data from all sources must be synchronized in time. To accomplish this task, therefore, a perfectly matched measurement system consisting of HV-safe and robust measurement modules, ECU measurement technology and software for measurement data acquisition and real-time analysis is required.
The CSM HV Breakout Modules ensure the HV-safe measurement of the required currents and voltages with a high data rate and are robust enough for driving operation. Due to the space-saving installation the system can also be used in the test bench. The perfect match of CSM measurement modules and data acquisition software from Vector Informatik allows the relevant measurement data to be analyzed in real time.
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.
The HV Breakout Module (BM) Type 3.1 is suitable for three-phase current, voltage and power measurement at three-phase charging stations with HV voltage carrying cables with currents up to ±32 A.
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.
HV AD4 XW1000 measurement modules provide four analog inputs and are specifically designed for the measurement of high voltages in high-voltage environments.
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.
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.