Rugged Monitoring Solutions - Fiber Optic Temperature Sensors in Electric Vehicle Temperature Testing

Solutions

Customer application solutions that provide unique differentiation using fiber optic temperature sensors in E-mobility, Medical, Energy and other industry verticals

Fiber Optic Temperature Sensors in Electric Vehicle Temperature Testing

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

Battery Bank and Cells
  • Higher immunity to electromagnetic interferences increases the testing accuracy and repeatability
  • Faster response time of 0.1s to 1 ms helps in identifying sudden temperature increase within cells
  • Rugged sensor tip (vibration withstand capability of 8g) is suitable for all test conditions
  • Easy to reuse sensors and monitors; do not require recalibration or complex inputs to operate
  • The CANBUS is implemented to communication with dataloggers or car Battery Management System
Power Train and Electric Motors
  • Due to their dielectric nature sensors can be fitted within windings to measure direct hot spot
  • Safe to operate and test; FO sensors are being used in transformer windings up to 1000kV
  • Easy to use (Plug ad Play) sensors; no expensive calibration needed
  • Accurate testing of cooling system efficiency during the complete vehicle testing
  • Use CANBUS to communicate with other test systems / dataloggers
Charging Port
  • Direct installation at the charging port increases the accuracy testing
  • Sensors are safe to operate and test under high voltage conditions
  • Easy to reuse sensors and monitors; do not require recalibration or complex inputs to operate
  • Use CANBUS to communicate with other test systems / dataloggers
Power Electronics
  • The small sensors (up to 0.4mm diameter) that can fit into tiniest space into power electronics
  • Easy to reuse (Plug ad Play) sensors with dielectric replaceable tip; no expensive calibration needed
  • Accurate testing of cooling system efficiency during the complete vehicle testing
  • Use CANBUS to communicate with other test systems / dataloggers
HV Cables and Large Current Terminals
  • Direct installation at the joints and large current terminals to get maximum accuracy
  • Sensors are safe to operate and test for short-circuit testing applications
  • The small sensors (up to 0.4mm diameter) that can fit into tiniest space at joints and terminals
  • Easy to reuse (Plug ad Play) sensors with dielectric replaceable tip; no expensive calibration needed
  • Use CANBUS to communicate with other test systems / dataloggers



System Architecture

We provide range of fiber optic temperature sensors, monitors and accessories to 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 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.


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

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Suite 230
Quebec, QC
G1N 4N7 - CANADA

Call US: +1-418-767-0111

Email US: info@ruggedmonitoring.com

Web: www.ruggedmonitoring.com



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