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Use Cases
Use Cases

Efficiency Measurement of a HV Powertrain

Electric powertrains have to be tested during many development phases. The overall efficiency is an important parameter for further optimization. In this application example, you can learn how the overall efficiency of fully integrated electrical powertrains is calculated in real time.

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Background

Modern, fully integrated powertrains offer numerous advantages, including reduced space requirements. However, instrumentation for necessary measurements presents some challenges, as power cables between the individual components are often not accessible. For this reason, the system's overall efficiency has emerged as a relevant parameter for further optimization, as the measurement points for the acquisition of electrical input power and mechanical output power are accessible. Characteristic maps provide information in the impact of software changes, new components and functional developments on the overall efficiency.

Measurement task

Measurement of electrical input power and mechanical output power for the calculation of the overall efficiency.

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Challenge

To determine the overall efficiency, the electrical power in the high-voltage cables between the battery (simulator) and the inverter must be measured in a high-voltage-safe manner and with a high resolution. Furthermore, the mechanical power must be measured with speed-torque sensors and the data must be acquired close to the measurement point to avoid electro-magnetic (EMC) interference. In addition, the calculation of the overall efficiency should be done in real time in order to immediately register the effects of different load conditions.

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The CSM-Solution

The solution for this measurement task is found in the perfectly harmonized Vector CSM E-Mobility Measurement System, which combines precise measurement modules and powerful software.

  • A High-Voltage Breakout Module (HV BM) 1.2 measures current and voltage between the battery simulator and the inverter with a data rate of 1 MHz and 100% synchronous. For this purpose, the HV BM is simply inserted in the power cables.
  • The measurement data of speed torque sensors are recorded with a CNT evo MiniModule. Due to its compact design, the module can be installed close to the measurement point and EMC interference, which could affect long sensor cables, are avoided.
  • A XCP-Gateway pro collects the data of the two measurement modules and converts them into XCP-on-Ethernet.
  • Via a Vector network interface VX1000 the internal measurement variables are synchronously recorded and synchronized with the external measurement data via the "Precision Time Protocol (PTP)".
  • The calculation of the required power values (electrical input power and mechanical output power) and the overall efficiency is performed in the eMobilityAnalyzer function library for Vector vMeasure exp or CANape. Furthermore the internal measured variables can be correlated directly with the calculated performance values.
Efficiency Measurement in E-Mobility Measurement System
Presentation of the efficiency measurement in the systematics of the Vector CSM E-Mobility Measurement System
eMobilityAnalyzer DC Analysis
The DC Analysis function in the eMobilityAnalyzer function library is used to calculate the electrical input power in real time.
eMobilityAnalyzer Axle Power
The Axle Power function calculates the mechanical output power in real time. The overall efficiency can be determined based on both power values.
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Benefits

With the Vector CSM E-Mobility Measurement System, the calculation of the overall efficiency can be done in real time. Due to the robust and compact measurement modules, the measurement can be performed both on the test bench and in road tests. The test setup is shortened to a few components, which reduces the time required for the test setup and increases the quality of the measurement.

Furthermore, the Vector CSM E-Mobility Measurement System allows easy integration of additional measurement modules for further measurement variables, e.g. temperatures.

Download

Here you find the complete application report for download as PDF.

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