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Home Solutions Fiber Optic Temperature Sensors in Electric Vehicle Temperature Testing
SOLUTION'S SUMMARY
electric vehicle solutions summary

Temperature management is one of the most important part in the design, development and testing process of electric / hybrid vehicles. The performance and aging of all critical components of electric vehicle highly depend on the temperature distribution and developing hot spots within. Therefore,  faster and accurate temperature measurement is necessary at each stage of EV product development e.g. individual component level testing for identifying performance limits and temperature behavior of individual components, and fully assembled electric vehicles to ensure the overall performance and safety.

Electric / Hybrid vehicle design and architecture differs a lot from the traditional Petrol and Diesel vehicles. The shift from low voltage to high voltage (up to 1000V) connections and operations within the similar vehicle space (or some time lesser space) bring challenges in terms of safety, limited access and electromagnetic noise issues during testing and measurements. Fiber Optic technology based sensors e.g. Fiber Optic Temperature sensors are becoming more and more popular in testing Electric / Hybrid vehicles due to their immunity to electromagnetic field, ruggedness, smaller size, faster response, high accuracy and safety of operation.

BENEFITS

HV Cables and Large Current Terminals

  • Use CANBUS to communicate with other test systems / dataloggers
  • Easy to reuse (Plug ad Play) sensors with dielectric replaceable tip; no expensive calibration needed
  • The small sensors (up to 0.4mm diameter) that can fit into tiniest space at joints and terminals
  • Sensors are safe to operate and test for short-circuit testing applications
  • Direct installation at the joints and large current terminals to get maximum accuracy
HV Cables and Large Current Terminals

Power Electronics

  • Use CANBUS to communicate with other test systems / dataloggers
  • Accurate testing of cooling system efficiency during the complete vehicle testing
  • Easy to reuse (Plug ad Play) sensors with dielectric replaceable tip; no expensive calibration needed
  • The small sensors (up to 0.4mm diameter) that can fit into tiniest space into power electronics
Power Electronics

Charging Port

  • Use CANBUS to communicate with other test systems / dataloggers
  • Easy to reuse sensors and monitors; do not require recalibration or complex inputs to operate
  • Sensors are safe to operate and test under high voltage conditions
  • Direct installation at the charging port increases the accuracy testing
Power Electronics

Power Train and Electric Motors

  • Use CANBUS to communicate with other test systems / dataloggers
  • Accurate testing of cooling system efficiency during the complete vehicle testing
  • Easy to use (Plug ad Play) sensors; no expensive calibration needed
  • Safe to operate and test; FO sensors are being used in transformer windings up to 1000kV
  • Due to their dielectric nature sensors can be fitted within windings to measure direct hot spot
Power Electronics

Battery Bank and Cells

  • The CANBUS is implemented to communication with dataloggers or car Battery Management System
  • Easy to reuse sensors and monitors; do not require recalibration or complex inputs to operate
  • Rugged sensor tip (vibration withstand capability of 8g) is suitable for all test conditions
  • Faster response time of 0.1s to 1 ms helps in identifying sudden temperature increase within cells
  • Higher immunity to electromagnetic interferences increases the testing accuracy and repeatability
Power Electronics
SYSTEM ARCHITECTURE
electric vehicle systme architecture

We provide a range of fiber optic temperature sensors, monitors and accessories to the component as well as EV/HEV manufacturers. Fiber optic sensors and monitors are being used during the product testing of electric motors, batteries, power trains, power electronics, and charging ports. Similar sensors and monitors are also being used during the complete vehicle testing at car manufacturing plants or test laboratories.

Our solution supports both distributed and centralized architecture as shown in the below figure. Centralized architecture is mostly used by component manufacturers and distributed architecture is ideal for complete vehicle testing. FO sensor and modules are designed for harsh automotive test conditions and to fit into small spaces available into the test vehicles.

electric car battery testing equipment


emobility RELATED PRODUCTS
O201
Specifications
Measurement Range-80 °C to +300 °C (cryogenic 4 °K range optional)
Measurement range (Optional Range extensions)Down to 4 °K / Up to +300 °C
Resolution0.1°C
Accuracy±1.0 °C (+/- 0.2 °C in relative temperature)
Number of Channels1 - 8 Channels
USB (to use with Rugged connect windows software)1 sec interval on USB / Micro SD card
Config portUSB (to use with Rugged connect windows software)
R501
Specifications
Measurement Range-80 °C to +300 °C (cryogenic 4 °K range optional)
Resolution0.1 °C
Accuracy±1.0 °C (±0.2 °C in relative temperature)
Scan Rate200 ms / channel ( Optional: Faster scanning rates available)
Number of Channels2, 4, 6 and 8 channels
Serail PortRS485 with Modbus support
CANBUS PortCANBUS Master/Slave support for CAN Dataloggers
TSENS
Specifications
Temperature range-200 °C to +250 °C
Repeatability0.2 °C
Accuracy absolute temperature+/- 0.8 °C
Accuracy relative temperature+/- 0.2 °C
Probe sheathing materialTeflon spiral-wrap
Tip materialTorlon (with disc) or Polyimide (no disc)
ConnectorStainless Alloy ST / Optional - Dielectric Torlon
LSENSB
Specifications
Temperature range-200 °C to +250 °C
Temperature range (Optional Range extensions) Down to 4 °K / Up to +300 °C
Repeatability0.2 °C
Accuracy absolute temperature+/- 0.8 °C
Accuracy relative temperature+/- 0.2 °C
Probe sheathing materialTeflon Coated, except for the sensor tip
ConnectorStainless Alloy / Optional - Dielectric

R-CONNECT

rconnect

Rugged connect provides remote visualization of temperature and other data being measured / monitored by various rugged monitoring systems. The software can connect to multiple monitoring devices for data collection and advance visualization. The intuitive user interface of the software is designed to give quick access to the most relevant information with highest level of data security.

  •  Cyber Security
  •  Real-time Data
  •  Data Logging
  •  Health Check

TERMINAL RINGS

Terminal rings for fiber optic probe tip mounting for places like cable terminals, battery etc.,

Extension Cables

Fiber Optic extension cables for applications where test equipment are very far from test object

Connectors

Fiber Optic Cable connectors (Metal and Dielectric) to connect two Fiber Optic and Extension cables

Disposable Tip

Disposable Dielectric Tip that allows Fiber Optic sensors to be reused

SYSTEM CONFIGURATION
Battery BankFO Temperature Sensors: 01 (for each Battery Cell) FO Temperature Monitor: 01 to 08 Multi-Channel Units (R501) with CANBUS support
AC MotorFO Temperature Sensors: 20 to 60 (depending on the design of the AC Motor) FO Temperature Monitor: 01 Multi-Channel Unit (R501) with CANBUS support
TransmissionFO Temperature Sensors: 02 FO Temperature Monitor: 02 Channel OEM Module (O201) with CANBUS support
Charging PortFO Temperature Sensors: 01 (for each Charging Port) FO Temperature Monitor: 02 Channel OEM Module (O201) with CANBUS support
Power ElectronicsFO Temperature Sensors: 04 to 08 (depending on the design) FO Temperature Monitor: 08 Channel OEM Module (O201) with CANBUS support
Cables & TerminalsFO Temperature Sensors: 01 (for each Joint and Termination) FO Temperature Monitor: 08 Channel OEM Module (O201) with CANBUS support
Complete EV/HEVFO Temperature Sensors: app. 50 to 125 fiber optic sensors FO Temperature Monitor: 05 to 16 OEM Modules (O201, 08-Channel) with CANBUS support