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.
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 of electrical input power and mechanical output power for the calculation of the overall efficiency.
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.
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.
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.
Here you find the complete application report for download as PDF.
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.
The HV Breakout Modules (BM) type 1.x have been specially designed for safe and precise single-phase measurement in HV voltage power cables. Inner conductor current and voltage are measured directly and the instantaneous power is calculated in the module.
The CNT evo is a high-precision measurement module designed for measuring frequencies, pulse widths, incremental displacement measurements, rotation angles, position measurement, event counting and period measurements.
Electromobility continues to gain momentum. Various energy storage, drive and charging systems pave the way to electric mobility. The development of high-voltage batteries, inverters and electric motors places high demands on measurement technology in order to obtain the right results for further optimization. Together with Vector Informatik, CSM has developed a measurement system that leaves nothing to be desired.
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 exp, 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.