Solutions for Safe Measurements in Electric Motors, HV Batteries & Components Thomas Schmerler V0.1 2017-06-06
Solutions for Safe Measurements of Temperature > Thermocouples > High precision RTD sensors Physical signals with standard sensors > Humidity, Pressure, Acceleration, Vibration, Strain Voltage and current > U up to 2000 V peak > I with precise Hall effect sensors or shunts 2
CSM HV Safety Concept Certified safety for the complete system from sensor to user Reinforced insulation according to EN 61010-1 Every single module routine tested up to 3100V DC High-voltage environment Low-voltage side CAN bus data acquisition via software or data logger 3
Definition of Insulation according to Safety Standard DIN EN 61010-1 Basic insulation Insulation of dangerous live parts as basic protection. Note: A basic insulation may also be used for functional purposes. Supplementary insulation Independent insulation which is used in addition to the basic insulation in order to protect against electrical shocks in the event of failure of the basic insulation. Double insulation Insulation consisting of the basic insulation and the supplementary insulation. Reinforced insulation Insulation providing protection against electrical shocks which is not inferior to the protection provided by double insulation. Note: REINFORCED INSULATION may consist of various layers which cannot be individually tested as SUPPLEMENTARY INSULATION or BASIC INSULATION. 4
Block Diagram Ni-CrNi Temperature Module High Voltage part Broken sensor detection Ref. Low Voltage part V in + PT1000 V in - Analog low pass ADC 16 bit K1 Functional isolation MC CAN controller CAN transceiver CAN BUS K4 Insulation barrier with reinforced insulation up to 846V for communication and power Power supply Power + Power GND 5
CSM HV Measurement Modules HV MiniModules CAN and EtherCAT For mobile use - Extremely compact, very robust and precise For installation close to the sensors IP 67, -40 C to +100 C HV 19 Modules for rack mounting Ideal for high channel counts, as precise as the HV MiniModules Use the same modules in test benches and in vehicles (trunk or passenger compartment) IP 65, -40 C to +85 C 6
HV Thermocouple Cable 7
Temperature Measurement at Batteries Standard batteries for hybrid and electrical powertrain applications are Lithium-ion batteries Lithium-ion batteries are very temperature sensitive, need to be heated and cooled In case the battery is too cold, it cannot be charged properly -25 C 10 C 25 C 60 C possible freezing of the electrolyte higher internal resistance leads to lower power output optimal temperature range rising of the cell internal resistance caused by degradation of the electrolyte 8
Temperature, Humidity and Pressure Measurements in Batteries Monitoring temperature balancing of each cell, busbar, in test stand and road test During charging, discharging, recuperation, cold start, etc. Very important due to temperature sensitivity of Lithium-ion batteries Typ. 60, up to 100 temperature sensors per battery (400 V battery) Verifying the BMS Verifying heating and cooling systems for the battery Detection of unwanted humidity inside the battery Verifying pressure compensation inside the battery Further Defining and verifying position of the standard temperate points inside battery 9
Temperature, Humidity and Pressure Measurements in Batteries Measurement Modules HV PT-TBM 8 HV TH-TBM 8 HV AD-TBM 4+ Pressure & humidity sensor 10
Temperature Measurements in High-Voltage Environment Benefits of thermocouples type K Various measurement tips available 4 sensors per 8-pin connector Various mounting options Temperature range -100 C to +1372 C Benefits of PT100/PT1000 RTD sensors Very high accuracy, better ± 0.3 C Extremely thin foils 0.7 mm available Mechanically robust to apply between battery cells 11
Precise Temperature Measurement in HV Batteries This rack with 10 HV PT-TBM 8 Modules for 80 RTD sensors was used in climatic Battery Test Stand. It came back to CSM for Isolation Test and Calibration. Now it is used in Vehicle Road Test. 12
Temperature & analog Measurements in Power Electronics Typically 16, up to 60 temperatures to monitor the different temperature ranges of the electrical components inside control unit and inverter Measuring switching voltages, etc. in addition to temperatures Sensors instrumented usually by power electronics manufacturer 4 HV THMM 4 HV ADMM 4 13
High Speed HV Power Measurements Measuring Calculating Voltage U and current I Up to 1 MHz per channel Time synchronization 1 µ s U up to 1.000 V continuously, up to 2.000 V peaks Power active (effective) power apparent power reactive power R.M.S. voltage (U eff ) R.M.S. current (I eff ) Phase displacement (cos φ) Using CSM HV Modules Using Vector CANape or vmeasure EXP 14
High Speed HV Power Measurements 1. E-Motor 2. HV-Battery 2 3. ECU 4. Inverter 5. Break-Out Box 3 4 5 1 15
High Speed HV Power Measurements HV battery Inverter AC (PWM 10 khz) Electrical engine DC M U 1 I 1 U 2 U 3 U 4 I 2 I 3 I 4 vmeasure, CANape XCP-Gateway HV ECAT ADMM HS ECAT ADMM HS XCP-on-Ethernet EtherCAT 16
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High Speed synchronized Data Acquisition of U, I and ECU data AC (PWM 10 khz) Electrical engine Vector VX 1xxx Serial POD M XCP-on- Ethernet ECU with Inverter R R R artificial neutral point Vector Sync U 1 U 2 U 3 I 1 I 2 I 3 XCP-Gateway HV ECAT ADMM HS ECAT ADMM HS vmeasure Exp, CANape EtherCAT 18
After Sales Support HV Insulation Test Standv Proper function of HV insulation of modules should be monitored during lifetime Recommend yearly and after dedicated incidents CSM HV Insulation Test Stand package: PC based Insulation Test Software to execute Insulation Test automatically Self-test adapters All necessary accessories High potential tester (optional) 19
For more information about Vector and our products please visit www.vector.com Author: Schmerler, Thomas Vector Germany 20 2017. Vector Informatik GmbH. All rights reserved. Any distribution or copying is subject to prior written approval by Vector. V0.1 2017-06-06