Download Challenges of EMC Testing on Hybrid Vehicle and Electric Vehicle

Albatross Projects GmbH
Presentation for IEEE HK EMC Society
Date: 24th November 2012
Jeffrey Tsang
Company Introduction
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Albatross Projects GmbH
196X
1989
1999
Head Quarter – Germany
3 Major Business Areas:
● Tempest
● Medical Shield Room
● Anechoic Chambers
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Albatross Projects GmbH
3m chamber
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Albatross Projects GmbH
10m Vehicle Chamber:
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Albatross Projects GmbH
Special Design Anechoic Chambers:
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Albatross Projects GmbH
Special Design Anechoic Chambers:
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Introduction of EMC Testing for High Voltage
Component in Hybrid and Electric Vehicle
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Today Technology
● Vehicle with combustion engine
● Hybrid Electric Vehicle
● Plug-in Hybrid Electric Vehicle
● Electric Vehicle
High voltage system:
• Battery - Can be up to 800Vdc
• Inverter: DC/AC, DC/DC
• Electric Motor: AC or DC
Reference : BOSCH Automotive Technology
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Today Technology
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Drive Mode
Reference : Teseq Beijing EMC Exhibition Beijing 2009
Internal
Combustion Engine
Starter/Alternator/
Electric Motor
Transmission
Electrical Drive
“Power Assist”
Recuperation
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Layout of Hybrid Vehicle
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High Voltage System
Reference : EE TIMES Automotive
October 06, 2010 | Frank Forster | 222901126
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Full Vehicle Test Vs Components Test
Cost breakdown
Comparison VEHICLE - COMPONENTS
Vehicle testing
Component testing
Test
[unit factor]
Time
[unit factor]
Engineer & Labor
[unit factor]
1
5 - 10
3-5
0.3 - 0.5
1
1-2
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Test Flow
●
Automotive R&D Process on EMC componets
R&D start
A-Sample
B-Sample
C-Sample
SOP
Entire timeframe: 2 – 3 years of R&D
Vehicle test
●
EMC test for a full vehicle is extremely difficuly for trouble-shooting
●
Must more cost effective and efficieny to start testing in componet level
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High Voltage System in Hybrid/Electric Vehicle
● Basic Model
High-voltage battery or fuel cell
with complementary DC/DC
converter
Auxiliary Power Train
Low-voltage
vehicle
electronics
– The EMC requirements on hybrid-, electric and even fuel cell power trains are in
general similarto each other.
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Common EMC Problems in HV system
● High DC voltage is converted into 3-phase AC voltage with variable
frequency
● This conversion process causes with high electro-magnetic field
strengths over a broad frequency range
● The noise is particularly high in the LF-, MF- and HF bands and can
also disturb the VHF bands
● Due to higher voltages, the noise level may increase up to 50x
compared to conventional vehicle electronics
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Common EMC Problems of Automotive Component
Testing on HV system
● Interference level on the traction leads, example
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Common EMC Problems of Automotive Component
Testing on HV system
● Interference level on a motor phase line
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Common EMC Problems of Automotive Component
Testing on HV system
● Pulses in the High-voltage Traction- and Phase Network
– Example for disturbance pulse in the Traction network
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Common EMC Problems of Automotive Component
Testing on HV system
● Coupling between HV and LV
Auxiliary devices
Signals
Data buses
Vehicle
electronics
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Common EMC Problems of Automotive Component
Testing on HV system
● Coupling between HV und LV
– The components show
 Sterical electro-magnetic coupling (components inside the same
housing)
 Functional coupling (data buses, functional links, power supply 12 V)
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Technical Challenges on Testing
● For the normal 12V/24V components, there are many EMC standards
with clear technical guideline to follows, such as CISPR25, ISO11452,
OEM standards .. etc
● These existing standards/guidelines are still applicable for testing HV
components (Battery, Inverter, Motor ..) but not enough.
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Technical Challenges on Testing
● High current and voltage may cause the following difficulties:
 Large and expensive components (coils, capacitors)
 Extensive weight
 Requirement of larger space
 Safety
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Technical Challenges on Testing
● Test setup
– Whole setup is done in shielded anechoic chamber
– Shall be able to simulate the operation of EUT under different Drive
Mode: Drive, Brake, Recuperation
– Variable test RPM
– Mechanical stability of motor oscillations
– Cooling system for test sample
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Test Setup in Chamber (CISPR25 ed.3)
The guideline in existing CISPR25 ed.3 is not good enough for testing HV
components
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Suggested Test Setup in Chamber
with HV Inverter and Motor
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Standard power supply
Shielded power supply
EUT
Shielded load simulator
Standard load simulator
Standard supply line
Shielded supply line
Low relative permittivity support
(εr<1,4) thickness 50mm
High quality coaxial cable e.g. double
shielded (50Ω)
Bulkhead connector
Lead through filter
Measuring instrument
Stimulation and monitoring system
Standard artificial network
Shielded artificial network
50Ω load
Optical fibre
Shielded box
Biconical antenna
Ground plane
Electric motor
Brake or propulsion motor
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Test Setup in Chamber
Reference: Mooser EMC Technik GmbH
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Technical Challenges on Testing
Shielding
RF Absorbing
Material
Motor under test in
chamber
Motor (Dynamometer) for
simulating road condition,
braking … etc
Solid Support
for motor
stability
Shaft
Solid Support /
Test Bed for
stability
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Technical Challenges on Testing
Chamber Outside
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Chamber Inside
Maintaining the shielding effectiveness
Maintaining the Anechoic Chamber RF performance
Insulating the noise penetration from connection shaft
Reinforcing the stability of chamber under motor vibration
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Technical Challenges on Testing
● Energy System
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Summary
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The major components of a high voltage system in Hybrid /Electric Vehicle: Battery,
Inverter, Electric Motor
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The noise level in high voltage system can be very high. This noise can be coupled to the
low voltage system
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The test setup for these major components is far more complicated because you need to
setup the load that can support different drive mode
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Additional instruments are required such as Energy System (DC power supply), Load
Simulator (Dynamometer)
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Special version of Anechoic Chamber for supporting the high voltage operation,
connection of Load Simulator and extra structural stability
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Thank You
Special thanks to the technical contribution from
Mooser EMC Technik GmbH / Mooser Consulting GmbH
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