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Albatross Projects GmbH

Presentation for IEEE HK EMC Society

Date: 24th November 2012

Jeffrey Tsang

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Company Introduction

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Albatross Projects GmbH

1989 1999

Head Quarter – Germany

3 Major Business Areas:

● Tempest

● Medical Shield Room

● Anechoic Chambers

196X

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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

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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

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Starter/Alternator/

Electric Motor

Internal

Combustion Engine

Transmission

“Power Assist”

Recuperation Electrical Drive

Reference : Teseq Beijing EMC Exhibition Beijing 2009

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Layout of Hybrid Vehicle

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High Voltage System

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Reference : EE TIMES Automotive

October 06, 2010 | Frank Forster | 222901126

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Full Vehicle Test Vs Components Test

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Cost breakdown Comparison VEHICLE - COMPONENTS

Test [unit factor]

Time [unit factor]

Engineer & Labor [unit factor]

Vehicle testing 1 5 - 10 3 - 5

Component testing 0.3 - 0.5 1 1 - 2

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Test Flow

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● Automotive R&D Process on EMC componets

● EMC test for a full vehicle is extremely difficuly for trouble-shooting

● Must more cost effective and efficieny to start testing in componet level

A-Sample B-Sample C-Sample SOP

Entire timeframe: 2 – 3 years of R&D

Vehicle test

R&D start

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High Voltage System in Hybrid/Electric Vehicle

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● Basic Model

– The EMC requirements on hybrid-, electric and even fuel cell power trains are in

general similarto each other.

High-voltage battery or fuel cell with complementary DC/DC converter

Low-voltage vehicle

electronics

Auxiliary Power Train

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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

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● Interference level on the traction leads, example

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Common EMC Problems of Automotive Component

Testing on HV system

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● Interference level on a motor phase line

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Common EMC Problems of Automotive Component

Testing on HV system

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● 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

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Data buses

Auxiliary devices

Vehicle electronics

Signals

● Coupling between HV and LV

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Common EMC Problems of Automotive Component

Testing on HV system

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● 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)

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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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1. Standard power supply

2. Shielded power supply

3. EUT

4. Shielded load simulator

5. Standard load simulator

6. Standard supply line

7. Shielded supply line

8. Low relative permittivity support

(εr<1,4) thickness 50mm

9. High quality coaxial cable e.g. double

shielded (50Ω)

10. Bulkhead connector

11. Lead through filter

12. Measuring instrument

13. Stimulation and monitoring system

14. Standard artificial network

15. Shielded artificial network

16. 50Ω load

17. Optical fibre

18. Shielded box

19. Biconical antenna

20. Ground plane

21. Electric motor

22. Brake or propulsion motor

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Test Setup in Chamber

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Reference: Mooser EMC Technik GmbH

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Technical Challenges on Testing

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Motor under test in

chamber Motor (Dynamometer) for

simulating road condition,

braking … etc

Shielding

Solid Support

for motor

stability Solid Support /

Test Bed for

stability

RF Absorbing

Material

Shaft

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Technical Challenges on Testing

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Chamber Inside Chamber Outside

● 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

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● Energy System

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Summary

● The major components of a high voltage system in Hybrid /Electric Vehicle: Battery,

Inverter, Electric Motor

● The noise level in high voltage system can be very high. This noise can be coupled to the

low voltage system

● The test setup for these major components is far more complicated because you need to

setup the load that can support different drive mode

● Additional instruments are required such as Energy System (DC power supply), Load

Simulator (Dynamometer)

● Special version of Anechoic Chamber for supporting the high voltage operation,

connection of Load Simulator and extra structural stability

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Special thanks to the technical contribution from

Mooser EMC Technik GmbH / Mooser Consulting GmbH

Thank You