Electrical Measurement for E-Mobility

E-Mobility

Reliable Equipment for High Voltage Applications

Increasing demands on testing due to rising battery voltage

Electrification is becoming increasingly prevalent in many different vehicle classes and types, and powertrain and vehicle component technology is developing enormously. This is particularly true of batteries, which continue to improve in terms of ­efficiency, size, charging time and capacity.

In order to increase vehicle performance, there is a clear trend toward higher voltages. Passenger cars are already on the market with a system voltage of 800 V. Heavy vehicles tend to exceed 1000 V, and designers are now planning 1200 V or 1500 V systems. Without higher voltages, current would have to be increased to boost motor performance. This would result in system losses and increase the need for additional copper to carry the current, ultimately leading to heavier vehicles.

Every electric and hybrid vehicle uses many high-voltage components that must be tested for function, safety and reliability during development and series production. In addition, automotive standards require extensive tests to qualify the components.

Electrical vehicles: High Voltage Components

E-Mobility requires many electrical measurement solutions, e.g. in the development, production and testing of high voltage components for the electrical vehicle (EV), as well as in onboard measurement, energy storage and the charging process.

High Voltage components in E-Mobility
  • HIL – Hardware in the Loop Simulation
  • EOL  – End-of-Line testing
  • Stress Screening

Many components have to be tested under load, thus highly dynamic processes with e.g. simulation/emulation of the powertrain are applied. Stress screening is also a frequently used method to detect early failures and for optimization during development. The aim is to ensure that all HV components operate reliably and safely in their specified voltage range in every conceivable driving situation.

Particular attention must be paid to effects such as voltage peaks due to abrupt load changes or coupling capacitances. It goes without saying that the signal transmission and isolation technology used must be suitable for high voltages in order to prevent any risk to users during testing in development and production or during operation. Validation in extreme driving or operating conditions ensures that the specific design of the HV on-board network offers sufficient reserves for unrestricted operation of the vehicle.

KNICK - Electrical Measurement and Control Equipment

For all these demanding tasks of measurement and testing, Knick provides a comprehensive range of high-pre­cision isolation transducers for measuring currents and voltages in the high-voltage segment. Additionally high-isolation, high-speed, and high-precision transducers are offered to control test equipment on high electrical potential.

Knick brings these features and specifications to a wide-range of standard products, but also has the capability to engineer custom solutions, depending on the specific application need.

Applications

Emobility HIL Hardware in the Loop for Heaters, BMS and traction inverters

Power Hardware in Loop HIL

HIL testing allows for prototype designs of equipment like traction inverters to be evaluated in various battery, load and fault situations, without the need to perform the trials with the inverters installed in dynamometers or the vehicles themselves.

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Emobility Pantograph Charger

DC Voltage Measurement for ­Interface between Vehicle and Charger

For battery-electric vehicles, high-speed charging by way of pantograph is possible. This involves contact between infrastructure equipment (with moving pantograph) and stationary charge-bars on the roof
of the vehicle. A DC switch box on roof of vehicle contains components that verify successful charge connection, and connects with other onboard systems.

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