CSM HV BM Split Modules for Current, Voltage and Power Measurement in Confined Spaces

CSM GmbH is excited to introduce its newest measurement technology solution for electric and hybrid vehicles where very confined installation space is available. The system provides high-frequency measurement of current, voltage and power directly, and safely, in high-voltage power cables. The new High-Voltage Breakout Module (HV BM) Split technology not only measures currents and voltages directly in the HV power cables but also in busbars and thus provides accurate measurement results. Thanks to their compact design, the HV BM Split Modules allow measurements in vehicles even where installation space for measurement technology is very limited, such as in production intent or competitive vehicles.

The HV BM Split Modules use the proven technology of the widely used CSM HV Breakout Modules, but due to the split design they allow measurements at measurement points where there is not enough space for the HV Breakout Modules. Current and voltage sensors (HV SBM - Split Breakout Modules) are connected to the HV SAM (Split Acquisition Module) measurement module via shielded, HV-safe sensor cables. This allows for distributed installation in test vehicles, even between vehicle components, in cable ducts and inside components such as e-axles or HV batteries.

The current sensors measure currents via customer-selected shunt modules (available measuring ranges from ±10 A to ±2,000 A) and are equipped with a sensor and memory for automatic online temperature compensation. In addition, the voltage tap HV- is located in the compact measurement module. The current sensors are available in different versions:

• HV SBM_I, for connection to the HV cable via cable glands and ring terminals (also available as a customized plug-and-play solution with connectors).
• HV SBM_I open, as pure encapsulated shunt module without housing for direct installation, e.g. in busbars

The voltage is tapped via variants of the HV SBM, which are also connected via ring terminals, or via a HV-safe sensor cable. The modules measure voltages up to ±1,000 V, with the measuring range dimensioned up to ±2,000 V.

The HV SBMs (except for the HV SBM_I open variant) are designed as robust and safely encapsulated housings, which ensure HV safety for components and users per EN61010:1-2010 and allow easy installation.

The HV SAM 1.1 measurement module for single-phase measurements acquires the current and voltage data of the connected HV SBM and transmits the date with up to 1 MHz via EtherCAT® network or at lower speeds via CAN bus. Optionally, the HV SAM 1.1 also calculates the RMS values of current and voltage, active, apparent and reactive power as well as phase angle and outputs these values via CAN.

For more comprehensive tests and the calculation of additional values in real time, the HV BM Split Modules are simply combined with other components from the Vector CSM E-Mobility Measurement System.

The HV BM Split Modules extend the portfolio of HV Breakout Modules for measurements in very confined spaces.