albatross projects gmbh - department of ee - city …emc/20121124p2.pdfseite 3 albatross projects...
TRANSCRIPT
Albatross Projects GmbH
Presentation for IEEE HK EMC Society
Date: 24th November 2012
Jeffrey Tsang
Seite
Company Introduction
Seite 3
Albatross Projects GmbH
1989 1999
Head Quarter – Germany
3 Major Business Areas:
● Tempest
● Medical Shield Room
● Anechoic Chambers
196X
Seite 4
Albatross Projects GmbH
3m chamber
Seite 5
Albatross Projects GmbH
10m Vehicle Chamber:
Seite 6
Albatross Projects GmbH
Special Design Anechoic Chambers:
Seite 7
Albatross Projects GmbH
Special Design Anechoic Chambers:
Seite
Introduction of EMC Testing for High Voltage
Component in Hybrid and Electric Vehicle
10
Seite
Today Technology
● Vehicle with combustion engine
● Hybrid Electric Vehicle
● Plug-in Hybrid Electric Vehicle
● Electric Vehicle
11
High voltage system:
• Battery - Can be up to 800Vdc
• Inverter: DC/AC, DC/DC
• Electric Motor: AC or DC
Reference : BOSCH Automotive Technology
Seite
Today Technology
12
Seite
Drive Mode
13
Starter/Alternator/
Electric Motor
Internal
Combustion Engine
Transmission
“Power Assist”
Recuperation Electrical Drive
Reference : Teseq Beijing EMC Exhibition Beijing 2009
Seite
Layout of Hybrid Vehicle
14
Seite
High Voltage System
15
Reference : EE TIMES Automotive
October 06, 2010 | Frank Forster | 222901126
Seite
Full Vehicle Test Vs Components Test
16
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
Seite
Test Flow
17
● 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
Seite
High Voltage System in Hybrid/Electric Vehicle
18
● 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
Seite
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
19
Seite
Common EMC Problems of Automotive Component
Testing on HV system
20
● Interference level on the traction leads, example
Seite
Common EMC Problems of Automotive Component
Testing on HV system
21
● Interference level on a motor phase line
Seite
Common EMC Problems of Automotive Component
Testing on HV system
22
● Pulses in the High-voltage Traction- and Phase Network
– Example for disturbance pulse in the Traction network
Seite
Common EMC Problems of Automotive Component
Testing on HV system
23
Data buses
Auxiliary devices
Vehicle electronics
Signals
● Coupling between HV and LV
Seite
Common EMC Problems of Automotive Component
Testing on HV system
24
● 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)
Seite
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.
25
Seite
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
26
Seite
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
27
Seite
Test Setup in Chamber (CISPR25 ed.3)
28
The guideline in existing CISPR25 ed.3 is not good enough for testing HV
components
Seite
Suggested Test Setup in Chamber
with HV Inverter and Motor
29
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
Seite
Test Setup in Chamber
30
Reference: Mooser EMC Technik GmbH
Seite
Technical Challenges on Testing
31
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
Seite
Technical Challenges on Testing
32
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
Seite
Technical Challenges on Testing
33
● Energy System
Seite
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
34
Seite 35
Special thanks to the technical contribution from
Mooser EMC Technik GmbH / Mooser Consulting GmbH
Thank You