Automotive
High voltage component testing for electric vehicles
By Robert Campling, senior manager at TÜV SÜD - a global product testing and certification organisation.
T
he pressure is on for automotive manufacturers to develop new technologies that effectively support global decarbonisation goals and consumer demand
for electric vehicles (EVs). While EV technologies have developed at a pace, the industry’s ability to deliver this transition effectively represents major challenges. To operate seamlessly and efficiently, electrically powered vehicles can no longer rely on the standard low-voltage (LV) 12-volt electrical systems that are used
14 February 2025
to power conventional vehicles. Instead, they depend on the use of high-voltage (HV) electrical systems and equipment to generate sufficient energy to power the engine and other essential EV components. To meet the growing market demand, the automotive industry is focused on speeding up EV development and production, which includes the integration of new and advanced HV technologies into vehicles, such as on-board chargers, HV batteries, DC/DC converters, and E-Motors and DC/ AC inverters.
Components in Electronics
These HV components are critical to the smooth operation of EVs and must be of high quality, as well as designed to withstand the rigours of daily use. However, as they are based on advanced high-voltage systems that can reach up to 1,500 volts, this brings increased safety risks which must be managed to ensure passenger and operator safety. It’s therefore vital that manufacturers prioritise the safety of their HV components and ensure they are designed to meet stringent safety standards.
However, testing HV systems and equipment to ensure their performance under anticipated operating conditions can present numerous challenges for component manufacturers. This is because HV components are generally far more technically complex than their LV counterparts. Thoroughly testing such sophisticated components requires a more complex testing setup. For example, this may include external power supplies to power a component during testing, software, methods of communicating with
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