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.
Individual components and also the entire HV electrical system of electric and hybrid vehicles are tested extensively in simulations and on test benches. However, measurements and analyses during test drives are indispensable to verify the developments under real conditions.
For precise and fast measurements of currents and voltages in the HV vehicle electrical system, the HV Breakout Modules are a proven solution: Measurements with active measurement shunts (with automatic temperature compensation) directly in the HV power cables provide precise and phase-accurate measurement results. At some measurement points, however, the available installation space for installing the HV Breakout Modules may be too small.
Measurement of current, voltage and power in the HV vehicle electrical system during test drives to verify development steps.
The cables of the HV vehicle electrical system are laid where there is space: tightly packed between components or in cable ducts. The measurement technology must have a correspondingly compact design and be able to be used in a decentralized manner in order to be installed under these space conditions.
The small design of the measurement technology should nevertheless not lead to compromises in measurement accuracy: Interference and phase shift should be avoided and the measurement should be carried out directly in the inner conductor. Furthermore, value acquisition should be made at a high data rate to allow for more advanced analyses.
Last but not least, the measurement technology must of course ensure HV safety for users and surrounding systems through suitable protective measures.
For the safe and precise measurement of current and voltage HV BM Split Modules are used. These use the same measurement principle as the HV Breakout Modules, but the three main components (measurement modules and acquisition module) are installed in separate small and HV-safe housings. This allows the HV BM Split Modules to be flexibly installed wherever space is available.
By separating the sensor modules and the measurement module, the HV BM Split Modules can also be used at measurement points where there is little space for installing the measurement technology.
Since the proven technology of the HV Breakout Modules is used in the HV BM Split modules, precise measurement results can be achieved for current, voltage and power measurement. In particular, current measurement via the active shunt modules directly in the inner conductor minimizes external interference and allows accurate analyses in the HV vehicle electrical system. Pseudo-signals, hysteresis effects, system-related noise, characteristic shift or offset errors are virtually non-existent with CSM shunt technology.
Power data can also be calculated directly in the measurement module. If more in-depth analyses are to be performed, further components from the Vector CSM E-Mobility Measurement System are available. This allows, on the one hand, powerful analyses in real time and, on the other hand, the simple integration of further measurement technology for the acquisition of additional measured values, such as temperatures and data from vehicle buses and control units.
The HV BM Split Modules use the proven technology of the HV Breakout Modules for fast and precise measurement of internal conductor current, voltage and power even in confined spaces. HV BM Split Modules can be used to perform measurements in HV power cables or also on busbars.
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.
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.
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.