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An all-in-one solution for measuring temperature and humidity in HV batteries requires minimal installation effort and has little impact on the battery housing
Testing of electric vehicles often involves not only examination of the electric powertrain but also measurement of the high-voltage battery assembly. Temperature and humidity are of particular importance. Both values must not exceed certain limits, otherwise safe operation cannot be ensured. Therefore, powertrain batteries must undergo very precise testing to determine limit values. This close monitoring of many temperature and humidity levels on all components of the high-voltage battery provides an accurate picture of the processes inside.
But to do so properly calls for a large number of measurement points to be installed in a very confined space. This is a challenge during testing: how can this requirement be met without excessive impact on the battery and its housing? After all, the more intact the test specimen remains, the more realistic the results of the measurements will be.
Another critical aspect to take into account is that the entire measurement system must be HV-safe to prevent injury to personnel or damage to property.
The HV DTemp measurement system developed by CSM is designed for comprehensive and precise temperature and humidity measurements inside high-voltage batteries. The miniaturized and interference-proof IC temperature sensors not only offer a measurement accuracy of ±0.1 to ±0.25°C but can also be customized to suit specific requirements. Depending on the application, there are individual options for implementing the sensors, for example as molded individual sensors or mounted on an ultra-thin, flexible circuit – ideal for measurements between all common battery cell types: cylindrical, prismatic or pouch.
Additionally, humidity sensors can be easily integrated into the system. These have an accuracy of 0.5% and can use any of the 512 measurement points. The ratio of temperature and humidity sensors within the measurement setup can be freely selected.
Four individual sensors – for temperature or humidity – can be combined to form a sensor module, and up to 64 sensors can be connected to eight controllers. The HV DTemp controllers handle the addressing and power supply of the sensors. As with all components of the HV DTemp system, the compact, robust design is key. The controllers transmit all signals bundled via a single HV-safe cable to the central unit. For the resulting maximum possible 512 measurement points, the battery housing therefore only requires one breakthrough. The central unit controls the entire measurement system and supplies all components with the necessary supply voltage. All signals are transmitted via CAN in digital form, minimizing the risk of malfunction.
