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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.
- HV Breakout Module (BM) 1.2
Single-phase current and voltage measurement on separate HV- and HV+ cables - Converters and consumers
Switching power electronics causes voltage ripples that can damage the system - HV Breakout Module (BM) 1.1
Single-phase current and voltage measurement in a single HV line - HV Breakout Modules
Are inserted directly into the HV lines and ensure safety - Mobile testing
A verification can only provide the desired results during a driving test
Background
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.
Measurement task
Precise measurement of current and voltage curves in the entire HV vehicle electrical system to prevent damage caused by current and voltage ripples.
Challenge
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 Measurement Solution
- HV Breakout Modules (BM) 1.1, 1.2 or 3.1
Are inserted directly into the HV cables and measure precisely single-phase current and voltage - EtherCAT®
Allows data rates of up to 1 MHz - XCP-Gateway
Acquires the measurement data synchronously and converts them into the XCP-on-Ethernet protocol - Vector interface
Acquires the data from the vehicle control unit - Vector vMeasure / CANape
The software aquires all data synchronously and analyzes the signals in real time. An online power calculation is also possible.
- HV Breakout Modules 1.1, HV Breakout Modules 1.2 or HV Breakout Modules 3.1 can be installed directly into the HV cables of the vehicle electrical system and are designed for high-voltage safe measurement applications even under the harsh conditions of a road test. They measure voltage and currents directly in the module.
- On test benches, the HV Breakout Modules 1.2C can be connected to the HV power cables via PL500 connectors. This facilitates the exchange of individual DUTs.
- Alternatively, voltages can also be measured with a measurement module HV AD4 XW1000.
- The data are transmited via XCP-Gateways to the DAQ.
- The Vector software vMeasure analyzes the signals in real time and additionally acquires the ECU measurement data synchronously. With the eMobilityAnalyzer an online power calculation is possible.
Benefits
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.
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
HV Breakout Module 3.1
Three-phase measurement of internal conductor current, voltage and instantaneous power
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.
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.
HV AD ECAT Measurement Module
Measurement Ranges up to ±1000 V and up to 1 MHz data rate
The HV AD4 XW1000 measurement module provides four analog inputs and is specifically designed for the measurement of high voltages in high-voltage environments.
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.
