High Voltage Safe Measurement Systems, Dr. Jürgen Braunstein < Computer-Systeme-Messtechnik Innovative Measurement and Data Technology
Solutions for Safe Measurements of Temperature Thermocouples High precision RTD sensors Physical signals with standard sensors Humidity, Pressure, Acceleration, Vibration, Strain Voltage and current V up to ±20 V for sensors, ±90 V for cells V up to ±1 kv DC/AC eff and ±2 kv peak of spikes I with precise Hall effect sensors or shunts up to ±1 ka Computer-Systeme-Messtechnik Sep. 2017 2
CSM HV Safety Concept Certified safety for the complete system from sensor to user Reinforced isolation according to EN 61010-1 Every single module routine tested up to 3.1 kv DC High-voltage environment Low-voltage side CAN bus data acquisition via software or data logger 3
Definition of isolation according to Safety Standard DIN EN 61010-1 Basic isolation Isolation of dangerous live parts as basic protection. Note: A basic isolation may also be used for functional purposes. Supplementary isolation Independent isolation which is used in addition to the basic isolation in order to protect against electrical shocks in the event of failure of the basic isolation. Double isolation Isolation consisting of the basic isolation and the supplementary isolation. Reinforced isolation Isolation providing protection against electrical shocks which is not inferior to the protection provided by double isolation. Note: REINFORCED ISOLATION may consist of various layers which cannot be individually tested as SUPPLEMENTARY ISOLATION or BASIC ISOLATION. 4
Block Diagram NiCr-Ni TC 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 Isolation barrier with reinforced isolation 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 Computer-Systeme-Messtechnik Sep. 2017 6
HV Thermocouple Cable 7
Temperature Measurement at/in 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 Benefits of PT100/PT1000 RTD sensors Various measurement tips available 4 sensors per 8-pin connector Various mounting options Temp. range -100 C to +1372 C Very high accuracy, better ±0.3 C Extremely thin foils 0.7 mm available Mechanically robust to apply between battery cells Computer-Systeme-Messtechnik Sep. 2017 11
Precise Temperature Measurement in HV Batteries This rack with 10 HV PT-TBM 8 modules for 80 RTD sensors was used in a climatic Battery Test Stand. It came back to CSM for Isolation Test and Calibration. Now it is used for a Vehicle Road Test. Computer-Systeme-Messtechnik Sep. 2017 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 V and current I Up to 1 MHz per channel Time synchronization 1 µs V up to 1,000 V continuously, up to 2,000 V peaks Application of CSM HV Modules Power active (effective) power apparent power reactive power rms voltage (V eff ) rms current (I eff ) Phase displacement (cos φ) Application of Vector CANape or vmeasure EXP Computer-Systeme-Messtechnik Sep. 2017 14
High Speed HV Power Measurements 1 E-Engine 2 3 4 HV-Battery ECU Inverter 2 5 Break-Out Box 3 4 5 1 Computer-Systeme-Messtechnik Sep. 2017 15
High Speed HV Power Measurements HV battery Inverter AC (PWM 10 khz) Electrical Engine DC M V 1 I 1 V 2 V 3 V 4 I 2 I 3 I 4 vmeasure, CANape, INCA XCP-Gateway HV ECAT ADMM HS ECAT ADMM HS XCP-on-Ethernet EtherCAT 16
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High Speed Synchronized Data Acquisition of I, V, and ECU data AC (PWM 10 khz) Electrical Engine Vector VX 1xxx Serial POD M XCP-on- Ethernet Vector Sync or PTP without cable ECU with Inverter V 1 R R R V 2 artificial neutral point V 3 I 1 I 2 I 3 XCP-Gateway HV ECAT ADMM HS ECAT ADMM HS vmeasure Exp, CANape EtherCAT 18
CSM Breakout Boxes for Data Acquisition of I and V and calculation of P Various breakout boxes under development EtherCAT output up to 1 MHz per channel Optional CAN output for data loggers Measurements of V up to ±1 kv DC/AC eff and ±2 kv peak of spikes I with shunts up to ±1 ka Calculation of power in real time for EtherCAT and CAN output 19
After Sales Support HV Isolation Test Stand Proper function of HV isolation of modules should be monitored during lifetime Recommend yearly and after dedicated incidents CSM HV Isolation Test Stand package: PC based Isolation Test Software to execute Isolation Test automatically Self-test adapters All necessary accessories High potential tester (optional) Computer-Systeme-Messtechnik Sep. 2017 20
More detailed Information requested? Refer to Datasheets of CSM HV Modules and Accessories Technical Information: Operation of CSM HV Modules Presentation: Safe Temperature Measurement Our Website: www.csm.de 21