CSM HV Breakout Modules with PowerLok Connector System for Easy Handling on Test Benches
The new HV Breakout Module 1.2C is easily connected to the HV power cables via a PL500 connector system and allows single-phase measurements on separate HV+ and HV- cables.
CSM GmbH, a leader in innovative measurement and data technology for 38 years, presents new “C” ("Connector") variants of the popular High-voltage Breakout Modules (HV BM) for measuring current, voltage and power. The “C” variants have a simple and safe connection system which facilitates handling. The time required for measurement setup is significantly reduced. In addition, the new HV Breakout Modules “C” can be easily unplugged for calibration.
HV Breakout Module 3.3C and HV Breakout Module 1.2C with PowerLok connector system for easy test bench measurement setup. Image used courtesy of CSM
Similarly, but with a PL300 connector system, the HV Breakout Module 3.3C is connected to the HV cables, e.g. between inverters and electric motors. The HV BM 3.3C measures voltages U12, U23, U31 and internal conductor currents of L1, L2, and L3 with a measurement data rate of up to 2 MHz per measured variable. The measurement data is transferred to the measuring computer via CAN and EtherCAT® (HV BM 1.2C) or XCP-on-Ethernet (HV BM 3.3C).
The HV Breakout Module 1.2C is connected to HV power cables via a PL500 connector system. Image used courtesy of CSM
The PowerLok connectors are designed for operating currents up to 800 A. They include a quick-lock lever with connection position aid and a socket housing with integrated high-voltage locking for high vibrations. When mated, the connectors provide IP67 protection. Due to the robust design, the connectors are also suitable for a high number of mating cycles.
Appropriate crimping tools are available for attaching the appropriate connectors to the HV cables. This also allows connectors to be attached to the cables directly on site.
As electromobility continues to develop, the amount of testing required to verify different variants and generations of components also continues to increase. New components are constantly being integrated into the platforms for electric powertrains, and their interaction must be analyzed. The test benches must therefore be adapted quickly and flexibly to the respective requirements of the testing tasks.
HV Breakout Module 3.3C ready for measurements on the test bench. Image used courtesy of CSM
The new HV BM “C” variants simplify the necessary conversion work on the test bench.
In addition, they simplify the coupling of different test bench setups: Using the HV BM 1.2C, an electric powertrain can be easily reconnected to a battery simulator, to a high-voltage battery or to a fuel cell. Adding other components to the test setup is also simplified. If, for example, a PTC heater or a braking resistor is to be added in addition to the electric powertrain, the components can simply be plugged into the HV BM “C” variants. On electric motor or powertrain test benches, the HV BM 3.3C makes it easy to change DUTs (e.g. inverters and electric motors) via the PowerLok connectors.
Measurement setup for real-time efficiency analysis of an electric power train with two electric motors on the test bench: The "C" variants of the HV Breakout Modules are connected to the HV cables via PowerLok plug-in systems. This allows the measurement setup to be set up quickly and individual DUTs to be changed. Image used courtesy of CSM
With the HV Breakout Modules as a major part of the larger Vector CSM E-Mobility Measurement System, the necessary measurements and power analyses for efficiencies of individual components or the complete powertrain are performed in real time. With the harmonized measurement system, many test tasks can be easily implemented and the measurement setup can be easily expanded with additional measurement modules for the acquisition of further physical variables or data from control units.
CSM is a leading, highly innovative manufacturer of decentralized networked, robust measurement technology and data loggers for applications in vehicles and test benches. We have been setting technological standards in this field for over 35 years. Our products are successfully used worldwide by almost all manufacturers of passenger cars, commercial, agricultural, and material handling vehicles as well as their suppliers and service providers.
Continuous innovation and long-term satisfied customers are our guarantee for success. With our high-voltage safe measurement and breakout modules developed for fast and synchronous measurements on electric and hybrid vehicles, we actively accompany our customers’ transformation towards eMobility.