Electric VehicleEnergy - Efficiency - Testing

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Introduction - Energy & Efficiency analyis

New registrations of electric vehicles hit each year a new record. The technology is developing fast, especially to increase performance and range of electric vehicles. The determination of the energy consumption is already a well-discussed topic as results can deviate heavily from the manufacturers specification. Tests according to old driving cycles (like the NEDC) are not sufficient. Hot or cold weather conditions as well as the driving behaviour and driving route can influence the results significant. The new defined driving cycle WLTP and especially the coming Real-Drive-Tests (RDE) should ensure more reliable energy consumption specifications.

HardwareThe EV-POWER sensors are designed exactly for the needs of accurate energy consumption measurements at electric vehicles .... at all driving conditions. The sensors are easy-to-mount (any kind of HV connector possible) and safe measurements are ensured. There are no modifications at the vehicles needed and no high-voltage cables for measurement need to be guided inside the motor- or compartment room. Shunt-based current sensing with automatic temperature correction allows measuring very low (50mA) as well as very high currents (500A) for the whole operating temperature range with highest accuracy. Further voltage and current are measured without the shield of the HV-cables (typically the problem using current clamps). Easy integration of GPS, Video, CAN-data and other analog & digital signals (see DEWEnet brochure) complements the hardware features.

SoftwareThe connectivity allows you to choose the ideal software for your application. Whether you integrate the sensor in existing CAN-based measurement systems (dbc-file), or using DEWESoft® for dynamic measurements ... or using the state-of-the art CLOUD solution which is an unique tool for fleet testing or Real-drive tests as you can access the data all over the world.

ReportFinally, report generation templates should support you to get test reports as fast as possible .... after or during your testdrives. Analysis for different driving situations (e.g. energy consumption from 40 to 50 km/h) as well as energy balance charts, statistics and motor evaluation gives you an excellent overview of your electric vehicle.

Enjoy driving electric your DEWEnet Team

CAN/USB converter

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Application Example

MicroLog or CAN-Logger or Display

Measure all of your High-Voltage (HV) and Low Voltage (LV) DC loads with the EV-Power sensors. (Battery, Motor, Heating, Air Conditioning, DC/DC, etc.)

Connect to MicroLog CAN logger or DEWESoft®

Get an sophisticated ENERGY BALANCE report about your test drive including special analysis for different driving situations.

” Know everything about your Electric Vehicle after one testdrive”

EV-POWER-x00ACurrent, Voltage, Power

DangerОпасностьPeligroPerigoNebezpečíTehlike危險

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Key Features

Perfect for dynamic measurements from mA to kA Temperature correction to achieve highest accuracy from -40°C to +100°C No influence of shielded High-Voltage cables

No High Voltage cables for measurement inside drive or motor compartment room

No modifications at vehicle needed Plug & Play

Wide Operating temperature range (-40°C to +100°C) Low Power Consumption Integrated Temperature logging

Any kind of connector possible Z-coded connectors Rent or Rebuild of sensors possible

AC Power integration possible Motor & Inverter evaluation Measurement of any kind of other signals

High-Precise shunt-based current measurement

Easy and Safe measurements

Flexible

Real Drive Tests

AC Power and other signals

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Technical Specifications

Power & Energy (using DEWESoft® or cloud solution)Typical accuracy ±0.2 %reading

Total accuracy ±0.7 %reading

Analog InputsAD conversion 16 bitSampling rate 4 kHz

Communication CANbus 2.0Output rate 1 kHz*, 500 Hz, 100 Hz, 10 Hz, 1 Hz

Output channels Current, Voltage, TemperatureOperating Conditions

Operating temperature -40°C .. +100°CCurrent consumption 30 mA .. 80 mA

Supply voltage 5.5 V .. 40 VDimensions 123x96x38mm (EV-POWER-100A) / 185x115x56mm (EV-POWER-500A & EV-POWER-1000A)

Protection IP54

* only current selected

CurrentType EV-POWER-100A EV-POWER-500A EV-POWER-1000A A

Measurement range ±100 ±500 ±1000 ATypical accuracy ±0.1 %reading

Total accuracy ±0.5 %readingResolution 5 30 50 mA

VoltageVoltage range ± 1000 V

Typical accuracy ± 0.1 % of readingTotal accuracy ± 0.5 % of reading

Resolution 30 mVSafety category CAT II 1000 V / CAT III 600 V

Current sensing from 50 mA to 1000 A

Voltage up to 1000 V

Power, Energy, Efficiency

Plug & Play

4G

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Connectivity - Software

CAN DBC

LabVIEW®

CLOUD SOLUTION

easy & fast integration predefined dbc files Config Tool with dbc export

Repeatable Test procedures Customer-specific solutions Test-Bed operation

Fleet Testing Database Storage Online Live Data View

ideal for fleet testing

ideal for repeatable test procedures

Incl. OBDII data Incl. GPS data Incl. easy to use data viewer Incl. data reporting

to DEWESoft® to INCA (ETAS®)to CANape® (Vector®)to IPEmotion® (IPEtronik®)to LabView® (NI®)to DASYlab® (NI®)to any testbed software

CAN with .dbc file

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CLOUD Solution

The state-of-the art cloud solution allows you to collect and access data of all your test vehicles wherever you are right now. Just connect the Odos MicroLog to your EV-POWER system and/or car and stream all data on powerfull server with a lot of data ananlytics functionalities (online and offline).

The Odos MicroLog supports all common standards for CAN bus description and it is even possible to configure your MicroLog over the air .... from anywhere over the world... cabling was yesterday. MicroLog has a sim card integrated for data transfer and GPS to get comprehensive data of your testdrives.

The Cloud server can be accessed via any webbrowser ... from your PC, tablet or mobile phone. The Dashboard gives you an overview of all vehicles (fleet analysis) or just a certain one. Automated evaluation of vehicle systems, easy export to a number of formats and the report generator complements the features of the innovative Cloud solution.

Mobile Phone support

OBD2

4G Modem

GPS Sirf V Chip

Dual CAN

Accelerometer

UDS ISO 14229

CANdb

CAN Traffic

J1939

Reports

Realtime Display

Plugin Concept

DTC Auditor

Configurator

Alerts and trigger module

Data Export Module

Signal and GPS Analysis

Admin and User Accounts

Battery Energy 90 %

Charging/Discharging losses 10 %

+ 40° C

Grid Energy 100 %

26 %Battery Energy 90 %

Charging/Discharging losses 10 %

- 20° C

Grid Energy 100 %

REPORTMANUFACTURERS SPECIFICATION

NUMBER OF SAMPLES [%]

TIME [MIN]

ENERGY [KWH]

SPEC

IFIC

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PTIO

N [

KW

H/K

M]

MEASUREDDATA

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Energy (Min, Max, Ave, specific) Power (Min, Max, Ave) Recuperation Efficiency Table Torque, Speed, Velocity, Altitude Temperature, Weather, GPS track

Sankey Diagram for Energy flow

Visualisation of individual Power and Energy Consumption for whole test drive

Motor Heating Cooling Losses, etc

BASIC ENERGY REPORT

ENERGY BALANCE DIAGRAM

2D ENERGY CONSUMPTION CHART

Energy Balance Report

26 %

23 %

48 %

Battery Energy 90 %

Charging/Discharging losses 10 %2% DC/DC

Air Conditioning

1 % Losses

Motor 2

Motor 1

- 20° C

Grid Energy 100 %

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Electric test vehicle

33 %

29 %

30 %

4 % DC/DC

Air Conditioning

1 % Losses

Motor 2

Motor 1

26 %

23 %

48 %

2% DC/DC

Air Conditioning

1 % Losses

Motor 2

Motor 1

REPORT

SPEED [RPM]

TORQ

UE

[NM

]

EFFICIENCY [%]

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Special Energy Analysis for Speed classes (40-50 km/h, 50-60 km/h…) Uphill / Downhill Energy Recuperation

Energy Report for 12/24V/48V Example: 12 V Battery,

Waterpump, Fans, Blower, DC/DC, Auxiliaries, ….

AC Power Analysis Motor Losses Analysis Power Quality Analysis

(Harmonics, Unbalance etc.) AC Power Analysis required

Efficiency Mapping DQ Transformation

AC Power Analysis required

Fleet Test Data & Analysis Live Data View

DRIVING SITUATION ANALYSIS

LOW VOLTAGE ENERGY REPORT

MOTOR EVALUATION I (OPTIONAL)

MOTOR EVALUATION II (OPTIONAL)

CLOUD STORING (OPTIONAL)

4G

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Measure any additional signal with CANLOG

StrainCounter

Power

GPSTemperature

Vibration

OBDII

CAN

Current

Recuperation

Voltage

Energy

Waterproof version available!

Up to 64 Channel in one chassis

Any input channel combination with 8 or 4 plug in modules

Expandable to 1000 channels

Low power consumption 8 W (64 ch temperature measurement)

Direct CAN-bus interface

USB and Ethernet connection

Internal USB storage logger function

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Analog Inputs CANLOG CANLOGw (waterproof ) CANLOG single moduleMeasurement modules 8 4 8 4 1

System Sample rate 0.01 Hz to 1000 Hz/channel

CAN Bus Baudrates 50, 100, 125, 200, 250, 333.33, 500 and 1000 kBaud

Data format on USB logging open .csv format for Excel®, LabVIEW®, MATLAB®, DIAdem®, FlexPro® and many more

Supply voltage 8 .. 60 VDC (6VDC when operating), Current limited to 4 Ampere

Power consumption (excluding modules) 1.5 W -

System bus connector 2x Lemo 1B 4 pin for CAN and power supply

Logging function USB type for stick; Lemo 00 4-pin for start/stop logging -

Temperature range -40°C .. +85°C

Relative humidity 5 to 95 % (non condensing)

IP protection IP 44 IP 65

Dimensions 265 x 164 x 111 mm 162 x 164 x 111 mm 279 x 170 x 131 mm 177 x 170 x 131 mm 170 x 110 x 29 mm

Weight (excluding modules) 1.8 kg 1.2 kg 2.5 kg 1.8 kg 0.56 kg

Instruments

ModulesCL(w)-TH8-K CL(w)-TH8-UNI CL(w)-STG4-S CL(w)-CNT4 CL(w)-LV4 CL(w)-LV6 CL(w)-RTD6

Input channels8 type K

thermocouple 8 universal

thermocouple4 Strain gauge

4 counter 12 digital inputs

4 low voltage, separate exc.

6 low voltage, common exc.

6 universal RTD

Measurement typesThermocouple,

voltageThermocouple, voltage

Full-, half bridge

Event counting, frequency, duty cycle,

PWM, DI

Voltage, current

Voltage, current

Temperature (all RTD types), Resistance

Input ranges±15 mV .. 1.5 V -270 .. 1350°C

±15 mV .. 1.5 V FS on TC type

± 20 mV/V350 kHz,

32 bit counter±100 mV .. 60 V, ±

30 mA±100 mV .. 60 V, ±

30 mA-200°C .. 850°C;

2, 20 kΩ

Sensor excitation - -2.5 VDC or

2.5 VAC

2 .. 15 V (max. 100 mA)

0 V .. ±15 V, 60 mA

max. 0.6 W/Ch

0 V .. ±15 V, 100 mA,

max. 1.5 W total100 µA, 500 µA

Input connector mini TC mini TC 10 pin Lemo 1B 7 pin Lemo 1B 7 pin Lemo 1B 7 pin Lemo 1B 7 pin Lemo 1B

System Sample rate/channel 1000 S/sec 1000 S/sec 1000 S/sec 1000 S/sec 1000 S/sec 1000 S/sec 1000 S/sec

Isolation voltage 500 VDC 500 VDC 500 VDC 200 VDC 500 VDC 500 VDC 500 VDC

Power consumption (max.)

0,65 (1) W 0,65 (1) W 2.7 (3.5) W 2 (10) W 2.3 (9) W 1.9 (4) W 0.8 W

Environmental

Operating temperature -40°C ..+85°C -40°C ..+85°C -40°C ..+85°C1) -40°C .. +85°C1) -40°C .. +85°C1) -40°C .. +85°C1) -40°C .. +85°C

Relative humidity 5 to 95 % (non condensing)

1) -40°C .. +70°C with full excitation power

UVolt

TDegree

IAmpere

Automatic Energy Balance Report

Current Measurement from 50mA to 1000 A

Voltage Measurement up to 1000 V

Temperature Logging & Drift compensation

Plug & Play

Power, Energy, Efficiency

Headquarters

DEWEnet GmbHFöllinger Straße 258044 GrazAustria / Europe

Phone: +43 316 39 28 75E-Mail: sales@dewenet.comWeb: www.dewenet.com

Northern Europe

ODOSOLUTIONSNohabgatan 18aBuilding 73461 53 TrollhättanSweden

Phone: +46 70 36 12209E-Mail: info@ODOSolutions.comWeb: www.ODOSolutions.com

Asia Pacific

DEWEnet CHINA Ltd.Unit 1603-1606, 16th. FloorAlliance BuildingNo. 130-136 Connaught Road Central,Sheung WanHong Kong

Phone: +852 820 88723Fax: +852 820 88726 E-Mail: support@dewenet.comWeb: www.dewenet.com ©

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