High-voltage test stations and component qualification for electric and hybrid vehicles

Continuous monitoring of the insulation level (from megohms to gigohms) increases test efficiency and product quality

The manufacturers of electric or hybrid vehicles have high requirements for both the electrical insulation level of the vehicle as a whole and that of the high-voltage (HV) components. This, in turn, presents suppliers with major challenges in setting up and operating HV test stations and in HV component qualification. When delivered, values up to the giga-ohm range are required in order to be able to compensate ageing effects and wear. This requires special measurement technology, which ideally provides exact measurement results during the entire testing process. Bender GmbH & Co. KG in Grünberg offers the optimal solution for such applications with the insulation monitoring devices ISOMETER® isoHR685W or isoHR1685.

Electric or hybrid vehicles are becoming more and more common on the roads. This comes along with the constant improvement of batteries and electric drives by the manufacturers, on the one hand due to the high requirements such as the reduction of the CO2 emissions and on the other hand due to the growing competition. However, the focus is not only on optimising the main components of an electric vehicle, but also on regularly adapting and improving the individual HV components. The permanently changing demands are passed on directly from the vehicle manufacturers to the supplier industry.

Whereas in the past, the on-board networks in the automotive industry with DC 12 V, 24 V or 48 V were relatively uncritical for all parties involved, so-called HV on-board networks in electric vehicles impose completely different conditions on materials, manufacturing processes and test procedures. Depending on the vehicle type and engine power, on-board voltages of up to DC 800 V are used, which places enormous demands on the HV components. In addition, the HV components should mostly be able to be used maintenance-free over a service life (EOL) of 15 years.