CSM HV Breakout Modules with PowerLok connector system for easy handling on test benches

CSM GmbH, a leader in innovative measurement and data technology for 38 years, presents new “C” ("Connector") variants of the popular High-voltage Breakout Modules (HV BM) for measuring current, voltage and power. The “C” variants have a simple and safe connection system which facilitates handling. The time required for measurement setup is significantly reduced. In addition, the new HV Breakout Modules “C” can be easily unplugged for calibration.

The new HV Breakout Module 1.2C is easily connected to the HV power cables via a PL500 connector system and allows single-phase measurements on separate HV+ and HV- cables. Similarly, but with a PL300 connector system, the HV Breakout Module 3.3C is connected to the HV cables, e.g. between inverters and electric motors. The HV BM 3.3C measures voltages U₁₂, U₂₃, U₃₁ and internal conductor currents of L₁, L₂, and L₃ with a measurement data rate of up to 2 MHz per measured variable. The measurement data is transferred to the measuring computer via CAN and EtherCAT® (HV BM 1.2C) or XCP-on-Ethernet (HV BM 3.3C).

The PowerLok connectors are designed for operating currents up to 800 A. They include a quick-lock lever with connection position aid and a socket housing with integrated high-voltage locking for high vibrations. When mated, the connectors provide IP67 protection. Due to the robust design, the connectors are also suitable for a high number of mating cycles.

Appropriate crimping tools are available for attaching the appropriate connectors to the HV cables. This also allows connectors to be attached to the cables directly on site.

As electromobility continues to develop, the amount of testing required to verify different variants and generations of components also continues to increase. New components are constantly being integrated into the platforms for electric powertrains, and their interaction must be analyzed. The test benches must therefore be adapted quickly and flexibly to the respective requirements of the testing tasks.

The new HV BM “C” variants simplify the necessary conversion work on the test bench.

In addition, they simplify the coupling of different test bench setups: Using the HV BM 1.2C, an electric powertrain can be easily reconnected to a battery simulator, to a high-voltage battery or to a fuel cell. Adding other components to the test setup is also simplified. If, for example, a PTC heater or a braking resistor is to be added in addition to the electric powertrain, the components can simply be plugged into the HV BM “C” variants. On electric motor or powertrain test benches, the HV BM 3.3C makes it easy to change DUTs (e.g. inverters and electric motors) via the PowerLok connectors.

With the HV Breakout Modules as a major part of the larger Vector CSM E-Mobility Measurement System, the necessary measurements and power analyses for efficiencies of individual components or the complete powertrain are performed in real time. With the harmonized measurement system, many test tasks can be easily implemented and the measurement setup can be easily expanded with additional measurement modules for the acquisition of further physical variables or data from control units.