Evolution of the standard CISPR25 to the Ed4. Impact on the design of vehicle component chambers and Frankonia solution EDTC

Transcription

1 EMC Conference -- Turkey September 2015 Speaker: Richard Weininger Evolution of the standard CISPR25 to the Ed4. Impact on the design of vehicle component chambers and Frankonia solution EDTC

2 Contents New methods, new setups for bench testing of radiated electromagnetic energies Background for these new situation Why we need them and how we use them A closer look on the international standardization, the draft for CISPR 25 4th edition

3 Basic Topics Parts of EMC Frequency area / Time area Electromagnetic waves Pulses + Transients High frequent noise current + noise voltage Electrical overstress including electrostatic discharge ESD

4 Introduction EMC radiated and conducted emission of electromagnetic energies Vehicle Test Bench Test qualification test New for E-mobility qualification test compliance test R+D control test pre-compliance test shielded chassis dyno in a non-modified vehicle test chamber Modified bench test chamber

5 Basic Topics EMC in automotive E-motor systems Basically all the valid CISPR and ISO regulations have to be used as for the low voltage systems, too. CISPR 25 for emission measurements, will be enhanced in edition 4 by annex I ISO X for immunity to electromagnetic fields, modification just started yet ISO for electrostatic discharges (ESD) modification not started yet ISO 7637 for pulses and transients, there is a part 4 in preparation.

6 Basic Topics For E- and Hybrid-motors there are the same EMC protection targets than for combustion engines!! High voltage net don't have to interfere the low voltage net and especially the receiving equipment for broadcast and other transmitting services

7 Basic Topics New Aspects to reach the protection targets in EMC for E-motors: Vehicle testing: Is not much different to the conventional EMC For low frequencies (<30 MHz) a new measurement method is in planning (will become CISPR 36) Component testing: The shielded high voltage net with it s security aspects The shielded high voltage artificial networks The driven engine on/next the setup The adapted voltage limits for high voltage networks A cooling system for EUT and Motor

8 Basic Topics Preconditions: A High Voltage System with it s belonging electronics which is strongly decoupled from the Low Voltage System It can hardly be interfered by penetration with external interferences. One of the weak points is the battery management system. - Most aggressive noise sources are working next to sensitive electronics. - Direct galvanic feed through from the HV- to the NV-net

9 Board net topology HV Battery Battery Management System Shielded HV-Net Low voltage net 12/24V Bus- and sensor-lines LV - Battery Motor Management System Electric Vehicle Motor

10 EMC module test methods conventionally Overview Harness Artificial Network Perpherie EUT

11 Stripline Method for conventionally tests with test bench for CISPR 25 and ISO

12 Battery Management System Be careful when used! better Do not use it in your EMC-Chamber

13 First realization of a test bench - without a motor for design control

14 Setup constellation for design control with motor or substitution for conducted emission measurement on LV artificial networks

15 Setup constellation for design control with motor substitution for conducted emission measurement on HV artificial networks

16 Setup constellation for design control with motor substitution for radiated emission measurement

17 Standardisation Work First suggestions for the Standardization of radiated and conducted emission methods

18 Suggested standardized setup for conducted voltage emission measurement in HV und NV nets with E-motor 1. EUT 2. Ground plane 3. Low relative permittivity support (ε r 1,4) thickness 50mm Ω load 5. LV harness 6. HV harness 7. LV load simulator 8. HV load simulator 9. LV AN 10. HV AN 11. LV supply lines 12. HV-supply lines 13. LV power supply 12 V / 24 V / 48 V (should be placed on the bench) 14. Additional shielded box 15. Shielded HV power supply (should be shielded if placed inside the shielded room) 16. Power line filter 17. Lead trough filter 18. Bulk head connector 19. Stimulating and monitoring system 20. Measuring instrument 21. High quality coaxial cable e.g. double shielded (50Ω) 22. Optical fiber 23. Ground straps 24. Electric motor 25. Electric motor supply lines 26. Mechanical connection 27. Filtered mechanical bearing 28. Brake or propulsion motor

19 Suggested standardized setup for current emission measurement in HV und NV nets with motor 1. EUT 2. Ground plane 3. Low relative permittivity support (ε r 1,4) thickness 50mm 4. Current probe 5. LV harness 6. HV harness 7. LV load simulator 8. HV load simulator 9. LV AN 10. HV AN 11. LV supply lines 12. HV-supply lines 13. LV power supply 12 V / 24 V / 48 V (should be placed on the bench) 14. Additional shielded box 15. Shielded HV power supply (should be shielded if placed inside the shielded room) 16. Power line filter 17. Lead trough filter 18. Bulk head connector 19. Stimulating and monitoring system 20. Measuring instrument 21. High quality coaxial cable e.g. double shielded (50Ω) 22. Optical fiber 23. Ground straps 24. Electric motor 25. Three phase motor supply lines 26. Mechanical connection 27. Filtered mechanical bearing 28. Brake or propulsion motor 29. Shielded enclosure Ohm load

20 Standardized Setup for antenna measurement - with inverter/charger and motor 1. EUT 2. Ground plane 3. Low relative permittivity support (ε r 1,4) thickness 50mm 4. Ground straps 5. LV harness 6. HV harness 7. LV load simulator 8. HV load simulator 9. LV AN 10. HV AN 11. LV supply lines 12. HV-supply lines 13. LV power supply 12 V / 24 V / 48 V (should be placed on the bench) 14. Additional shielded box 15. Shielded HV power supply (should be shielded if placed inside the ALSE) 16. Power line filter 17. Lead trough filter 18. Bulk head connector 19. Stimulating and monitoring system 20. Measuring instrument 21. High quality coaxial cable e.g. double shielded (50Ω) 22. Optical fiber 23. Biconical antenna 24. RF absorber material 25. Electric motor 26. Electric motor supply lines 27. Mechanical connection 28. Filtered mechanical bearing 29. Brake or propulsion motor 30. AC or DC power mains 31. AN for AC or DC power mains 32. AC or DC charging load simulator

21 Bench Test Versus Vehicle test One of the most interesting and not yet answered topics: When the test setup becomes to complex for bench testing? When will be a vehicle test more effective?

22 Construction of shielded HV artificial network L1: 5 µh C1: 0.1 µf C2: 0.1 µf R1: 1 kω R2: 1 MΩ (discharging C2 to < 50 Vdc within 60 s) (voltage-resistance of C1 and C2 shall match with the supply voltages)! Measuring output

23 Standardisation Work First suggestions for the Standardization to detect the radiated and conducted decoupling factor

24 Measurement of decoupling factor between HV and LV part Voltage Method 1. EUT 2. Ground plane 3. Low relative permittivity support (ε r 1,4) thickness 50mm 4. Test signal coupling element 5. LV harness 6. HV harness 7. LV load simulator 8. HV load simulator 9. LV AN 10. HV AN 11. LV supply lines 12. HV-supply lines 13. LV power supply 12 V / 24 V / 48 V (should be placed on the bench) 14. Additional shielded box 15. HV power supply (should be shielded if placed inside the shielded enclosure) 16. Power line filter 17. Lead trough filter 18. Bulk head connector 19. Stimulating and monitoring system 20. Measuring instrument 21. High quality coaxial cable e.g. double shielded (50Ω) 22. Optical fiber 23. Ground straps 24. RF generator (may be placed inside the shielded box 14) Ohm load

25 Measurement of decoupling factor between HV and LV part Current Method 1. EUT 2. Ground plane 3. Low relative permittivity support (ε r 1,4) thickness 50mm 4. Test signal coupling element 5. LV harness 6. HV harness 7. LV load simulator 8. HV load simulator 9. LV AN 10. HV AN 11. LV supply lines 12. HV-supply lines 13. LV power supply 12 V / 24 V / 48 V (may be placed on the bench) 14. Additional shielded box, see annex B 15. HV power supply (should be shielded if placed inside the shielded enclosure) 16. Power line filter 17. Lead trough filter 18. Bulk head connector 19. Stimulating and monitoring system 20. Measuring instrument 21. High quality coaxial cable e.g. double shielded (50Ω) 22. Optical fiber 23. Ground straps 24. Shielded enclosure 25. RF generator (may be placed inside the shielded box 14) Ohm load 27. Current clamp

26 Measurement of decoupling factor between HV and LV part Radiation Method 1. EUT 2. Ground plane 3. Low relative permittivity support (ε r 1,4) thickness 50mm 4. Test signal coupling element (may be current clamp or capacitor) 5. LV harness 6. HV harness 7. LV load simulator 8. HV load simulator 9. LV AN 10. HV AN 11. LV supply lines 12. HV-supply lines 13. LV power supply 12 V / 24 V / 48 V (should be placed on the test bench) 14. Additional shielded box 15. HV power supply (should be shielded if placed inside shielded enclosure) 16. Power line filter 17. Lead trough filter 18. Bulk head connector 19. Stimulating and monitoring system 20. Measuring instrument 21. High quality coaxial cable e.g. double shielded (50Ω) 22. Optical fiber 23. Biconical antenna 24. RF absorber material 25. Ground straps 26. RF generator (may be placed inside the shielded box (14)) Ohm load

27 Measurement of decoupling factor between HV and LV part Voltage/Current Method Test Signal Injection and Calibration Calibration procedure for the RF-limit level Terminate the output of the not tested HV-AN with 50 ohms. Supply RF-power into the coupling element (5), either by current clamp or capacitive coupling. Measure the output level at the measuring port of the HV-AN (7). For all measurements from 150 khz to 108 MHz choose bandwidth 9 khz. Set the output-level to the specified test level from table 1 Calibration at one of both ports only, HV+ or HV-, is sufficient. 1. Ground plane 2. Additional shielded box 3. Ground straps Ω load 5. Test signal coupling element (may be current clamp or capacitor) Test setup for calibration of the test signal 6. HV load simulator 7. HV AN 8. HV-supply lines 9. Optical fibre 10. High quality coaxial cable e.g. double shielded (50Ω) 11. Lead trough filter 12. Stimulating and monitoring system 13. Power line filter 14. Shielded HV power supply (may be placed inside the ALSE) 15. Tracked HF-Test generator (may be placed inside the shielded box) 16. Bulk head connector 17. Measuring instrument

28 db Suggestion for 5 classes of the decoupling factor according to the 5 limit classes in CISPR 25 Coupling attenuation A A1 A2 A3 A A F MHz

29 Transfer impedance and DC resistance For example: typical values for available coaxial cables and interconnections DC-cable (< 6 m) DC-resistance of the shielding of the cable DC-resistance (housing socket plug cable shield) Transfer impedance Up to 2 MHz Transfer impedance At 30 MHz < 3 m /m < 10 m < 5 m /m < 100 m /m

30 Setup constellation for design control with a real motor Up to now there is less experience in realize hand able test setups Possible solutions shall have the premises: Most effective and economic!! EMC test Chambers must be modified!!

31 Schematic of an EMC test place for E-motors with turning motor inside the test chamber and steering equipment outside Drive Engine AC Supply Test Bench Power Supply Drive Engine E-motor ECU HV DC Supply Filter

32 Electro Drive Test Chamber EDTC by Frankonia

33 Electro Drive Test Chamber EDTC by Frankonia Loaded with a test setup by CISPR 25

34 Schematic of an EMC test place for E-motors with turning motor inside the test chamber Power supply HV Cooling system HV-LISN HF - clutch 50mm Insulation Power supply 12V + LISN - LISN DUT Motor Driving Engine Original length or standardized

35 Note!! All figures in the CISPR 25 Annex I are examples! For all those who have no closer requirements by a vehicle manufacturer. Due to the fact users have not enough experience for constucting a usable test setup, use your engineering capability to create a setup that works together with the car manufacturer 1. Test set-up The set-up is adapted from and is shown in Figure I.1. The shielding configuration and any protective ground connection should be representative of the vehicle application and shall be defined in the test plan. The battery charger ground connection shall also be defined in the test plan. EUTs and loads shall be connected to ground using impedance as defined in the test plan. The vehicle HV battery should be used; otherwise the external HV power supply shall be connected via feed-through-filtering. Unless otherwise specified in the test plan (e.g. use of original vehicle harnesses), the length of harnesses shall be as follows:

36 Thank you for your audience