A new module for 3-phase measurement of current and voltage for power analysis in the E-powertrain

CSM Gmbh, has announced the newest product to its suite of measurement modules to develop electric vehicles. This new HV Breakout-Module has been specifically designed to meet the international safety standards required to use equipment in high-voltage applications on electric vehicles. This new module simplifies the instrumentation, improves accuracy, and reduces costs than systems not designed for in-vehicle use. When combined with Vector Informatik's eMobility Analyzer, real-time power analysis can perform in the test bench and test vehicle.

The new HV Breakout Module (HV BM) 3.3 enables the electrical power analysis of vehicle engines for the first time without the use of classical power meters and current transformers. Therefore, the module is suitable for use in powertrain test benches and mobile, real-time measurement in the high-voltage electrical system of test vehicles.

The HV BM 3.3 samples current and voltage signals at 2 MS/s and sends the sampled values via XCP-on-Ethernet directly to the Vector Informatik software vMeasure exp or CANape. The measured raw data is stored and power values are calculated in real-time using the integrated eMobilityAnalyzer function library. The eMobilityAnalyzer calculates motor power values such as active power, apparent and reactive power, power factor, electrical speed, harmonics, total energy, or the motor windings' effective power. At the same time, an online graphical display of all measured values and power parameters is available.

In the HV Breakout Module 3.3, high-voltage cables up to 95 mm2 can be connected directly. High-voltage cables are fed into the module via suitable PG cable glands and connected with appropriately sized ring terminals. Alternatively, instead of PG glands, the HV BM 3.3C can also be supplied with 3-phase PowerLog connectors. This allows easy connection of DUTs, especially in powertrain test benches, to reduce changeover times. These connections, and the module itself, provide a system that meets EN 61010:1 requirements for using electronic equipment in high-voltage environments.

For 3-phase power measurement, the measurement circuit for currents and voltages is already installed in the module. This eliminates the need for cumbersome cabling and eliminates the associated interference. Phase currents and voltages up to 1,400 A and 2,000 V are sampled synchronously within 1 µs with the module. Complex phase correction for power measurement, as was previously expected, is no longer necessary. The direct A/D conversion in the module and transmission of digital samples avoids electromagnetic interference in the environment of high-speed traction inverters.

The number of channels for power analysis can be easily expanded: The measurement data of further HV Breakout Modules, for example, used between the battery (-ies) and inverter(s) or other vehicle components, are synchronously integrated in the measurement chain via an EtherCAT® interface. This enables power efficiency analysis of the components in the powertrain with minimal effort.

Additional HV-safe and conventional CSM MiniModules for measuring temperatures, vibration, torque, and speed can be added via a CAN interface to approach load points with temperature accuracy and record efficiency maps.

Time synchronization with other data sources, such as ECU data, is performed using PTP synchronization according to the IEEE1588 standard.

The HV BM 3.3 is designed for harsh environments and can operate in ambient temperatures from -40 °C to +125 °C. A high-voltage and interference-proof encapsulated design with temperature-compensated shunt modules ensure very high accuracy over the entire temperature range.