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Use Cases
Use Cases

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 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.

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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.

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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.

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The CSM-solution

  • HV Breakout Modules (BM) 1.1, 1.2 or 3.1 from CSM 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.
  • Alternatively, voltages can also be measured with a measurement module HV AD4 XW1000.
  • They measure voltage and currents directly in the module and transmit the data via XCP Gateways to the DAQ.
  • The Vector software vMeasure exp or CANape analyzes the signals in real time and additionally acquires the ECU measurement data synchronously. With the eMobilityAnalyzer an online power calculation is possible.
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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.

Download

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

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