ISO 7637:2,3. (7637:2) Transient Conduction for supply lines. □ Transient
Emissions. □ Transient Immunity. (7637:3) Transient Transmission for non-
supply ...
2011 IEEE International Symposium on Electromagnetic Compatibility FR-PM-2 August 14-19, 2011 – Long Beach, CA
This presentation is a joint project by Jastech EMC Consulting and TÜV SÜD America that looks at EMC testing of Energy Storage Systems (ESS) for Electric (EV) and Hybrid Electric Vehicles (HEV). The focus is to share the challenges and flexibility that a test facility needs to address in order to accommodate OEM approved Test Plans and development testing. The presentation is presented in 2 parts: 1.
“Defining the Test Methodology using System Engineering”, presented by James Muccioli from Jastech EMC Consulting, will discuss the different modules and functionality being integrated into the Energy Storage Systems using a System Engineering methodology of indentifying requirements and defining EMC objectives.
2.
“Test Laboratory Practical Implementation”, presented by Dale Sanders from Jastech EMC Consulting, will discuss the “how to” and flexible capability required that an automotive EMC Lab will need to have to test ESS Units. Several examples will be shown of how TÜV SÜD America addresses the physical size issues as well as equipment/facility required investments.
EMC test facilities want well defined test standards and test plans to follow for verification/validation testing (DV & PV).
Developing Standards, test methodologies or set-up criteria should be: y Done through work on standards committees y Defined during the design/development stage of a product. y Supported by test facility in developmental testing y Documented in DV/PV test plan y NOT interpreted or defined during verification/validation testing
In the past, component/module could typically get away with minimal instructions in a test plan or no test plan at all because: y Product is relatively simple and stand-alone y Generally have a “small” physical size y Fit well within defined test parameters of a standard
ESS are complex SYSTEMS that challenge typical EMC test facility accommodations and standards requirements.
For a quick comparison of typical component vs. ESS: y Normal automotive component ■ Size is typically under 1 cu. ft. (1’x1’x1’) ■ Weight under 10 lbs ■ Set-up time for testing 2-4 hours
y ESS ■ Size can range from 8 cu. ft. (2’x4’x1’) to 64 cu. ft. (4’x8’x2’) ■ Weight can range from 700 lbs to over 2500 lbs ■ Set-up time is double or more than normal automotive DUTs.
What are the big-picture ISSUES for a test facility to test ESS? y What are the considerations to apply Standards
written for small components to large ESS? y How do test facilities maintain integrity & compliance
to Standards and Accreditation bodies? y What flexibility is required in order to accommodate
ESS testing?
ESS are bigger and heavier than typical Automotive components.
Testing now involve high voltage (300-600 V) and high current (100-300 Amps)
Regulations, Standards & References y Occupational Health and Safety Administration (OSHA) Regulations: Subpart S-Electrical y y y y
29 CFR 1910.331-.335 National Fire Protection Association (NFPA) 70E: Standard for Electrical Safety in the Workplace Argonne National Laboratory: Practical Application of Electrical Safety Practices Sandia National Laboratories: Advanced Technology Development Program for LithiumIon Batteries Oklahoma State University: Electrical Safety
Procedures & Policies y TÜV Safety Procedures (Safe Working Practices) ■ Boundary Limits ■ PPE – Equipment & Tools ■ Lockout/Tagout ■ Energized Circuits, De-energized Circuits, Re-energizing Circuits y Personnel Training ■ Qualified Persons – One who has received training in and has demonstrated skills and knowledge in the construction and operation of electric equipment and installations and the hazards involved. ■ Unqualified Persons – have only limited training in safe work practices. y Contractors, Customers & Visitors y Hazard Identification and Response Procedures
EMC Testing of ESS is going to require investment and modification.
Can chamber floor handle the weight of ESS and equipment needed to lift?
Typical 3 meter modular chambers are not designed to support localized weight that ESS can present. For example: y Raise reflective ground plane (6 or
12 inch): 125 lbs./sq. ft. distributed y Point rating should not be over 200 lbs.
TÜV Solution - ESS testing is done in chamber with welded steel floor that is directly on top of concrete slab.
Welded steel floor on concrete
Raised modular floor
How to get access inside the chamber for lifting equipment? Typical 3 meter modular ALSE chambers are not designed to allow direct forklift access. NOTE: lip located on the floor used to secure doors needs to be protected from damage.
TÜV Solution y Double doors on chamber. y Employ forklift that have ability to
reach and traverse in chamber. y Custom built ramps to allow forklift in chamber.
ESS units may require compressed air or circulated liquid to cool ESS and/or loads. What options are available that maintain shield integrity of the Chamber?
TÜV Solution – Chamber is plumbed for water, air & hydraulic fluid.
Outside Chamber
Inside Chamber
Ground Plane & support tables in Chamber
In order to accommodate ESS size and comply with Ground Plane dimensional criteria, the Ground Plane will need to grow significantly from typical size.
In order for tables to support the weight of ESS, tables will need to be structurally redesigned.
TÜV Solution – custom built tables with large Ground Planes that can handle weight requirements of ESS.
Can the orientation of the chamber be modified to accommodate larger GND Plane and/or better access?
Chamber orientation must give consideration to: y Growth of GND plane y Dimensional constraints called
out in Standards y Access for lifting/moving equipment
TÜV Solution – Chamber and moving equipment allow for reconfiguration of chamber orientation.
What charging & power supply requirements are needed to support ESS testing?
Linear Power Supply y Voltage requirements y Current requirements
Chamber Filters y Rated Current
External charging systems Additional considerations
y ESS Battery Cell Operating Levels
need defined y Need charging procedure y Charging downtime affects test through-put timing. y Shielded High Voltage Cables
What Loads & Artificial Networks are now needed for High Voltage?
ABC 150/DCU Power Processing System Power Inverter from vehicle
ABC 150/DCU Power Processing System Bulkhead filter rating for Chamber y Facility electrical supply y Cabling to test set-up y Programming & Monitoring y
Passive Resistor y y y
Actual vehicle Load y y
Power rating Cooling Representative impedance Inverter Motors
LISN
Passive Resistor Bank
What monitoring & support equipment will be needed?
Fiber optic lines are needed for: y Video equipment y Audio equipment y Analog signals y CANBus (multiple busses?) y LINBus (multiple busses?)
Fiber optic converters ESS require more monitoring accommodations.
Meeting requirements for Automotive Standards
An ESS is generally tested to the following International Automotive EMC Standards or approved deviation thereof: CISPR 25 y Radiated Emissions (RE) y Conducted Emissions (CE) ■ Current Method ■ Voltage Method
ISO 10605 y Electro-Static Discharge (ESD) ■ Powered ■ Handling (non-powered)
Note: Examples shown in the next few slides have deviations in set-ups due to physical geometries which have been approved by customers.
ISO 7637:2,3 y (7637:2) Transient Conduction for supply lines ■ Transient Emissions ■ Transient Immunity y (7637:3) Transient Transmission for non-supply lines ■ Capacitive Coupling Clamp (CCC) ■ Direct Capacitive Coupling (DCC) ■ Inductive Coupling Clamp (ICC)
ISO 11452:2,4 y (11452:2) Radiated Immunity (RI) y (11452:4) Bulk Current Injection (BCI)
Shown is monopole set-up, additional setups include biconical, Log & Horn
Shown is Horn set-up
Additional Considerations y Electrical Testing Over Temperature y Customer monitoring equipment and system settings
Conclusion y Efficient testing throughput is needed for test facility
scheduling and economics. y Customer needs to work hand-in-hand with test lab for test plan development. ■ ■ ■ ■ ■
Safety Moving & handling Facility & test equipment requirements Details of set-up and functionality (engineering support) Customer needs to specify and sign-off on deviations due to physical size and system complexity
QUESTIONS ??? For more information or to contact us: http://www.Jastech-EMC.com, Phone (248) 876-4810 http://www.TUVAmerica.com, Phone (734) 455-4841
