Today, the voltages of traction batteries in electric vehicles are typically in the range of 400 to 800 V and may reach values of 1500 V in the future, since higher voltage allows higher power with lower losses. The energy in these storage systems is enormous and can cause considerable damage in the event of a fault. Safety devices in electric vehicles ensure that the high voltages and energies in the high-voltage batteries do not endanger anyone – neither drivers, passengers nor first responders during a rescue after an accident.
Even in the event of a crash, it must be ensured that no dangerous voltage reaches the vehicle body. For this purpose, fuses are used that disconnect the energy storage very reliably before live parts can bend and make contact. If a crash nevertheless causes a short circuit in the vehicle, currents of several kiloamperes must be reliably interrupted. This is done, for example, with so-called pyro fuses, which break the electrical connection by means of a small explosion, similar to the airbag igniters common in the automotive sector. Pyro fuses are safety-relevant components and must therefore be tested thoroughly.
To demonstrate the tripping behavior of such a component under simulated short-circuit conditions, a current source is required that can deliver several kiloamperes for a few milliseconds. In addition, it must generate a realistic battery voltage of up to 1500 V while the fuse trips.
IRS Systementwicklung and GvA Leistungselektronik work closely together to develop pulse current sources for up to 35 kA. This cooperation combines the many years of solid experience of GvA in power electronics, high-current design and system manufacturing with that of IRS in software, safety and measurement technology.
Features
- Peak currents up to 35 kA
- Voltage range up to 1500 V
- Pulse duration approx. 5 ms @ 30 kA
- Single-shot or optional multi-shot function with IGBT technology
Applications
The surge current test systems from GvA and IRS can be used to test various switching devices in the automotive sector.
The current focus is clearly on disconnecting traction batteries in the event of a crash, but applications in the energy sector have similar requirements.
The systems are used for design validation by manufacturers and test institutes.
In addition, sample tests in production with surge current test systems ensure the reliability of the products.
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