Automotive
components to extreme high and low temperatures and rapid temperature changes, to ensure the components function flawlessly.
Moisture and water-tightness testing: Verification of components’ resistance to moisture and water.
Vibration and shock testing: Simulation of vibration and shocks that may occur during driving on uneven roads or offroad terrain.
IP protection testing: Testing for protection against water and dust ingress.
Salt spray testing: Testing of components’ resistance to corrosion.
Robert Campling, senior manager at TÜV SÜD
the device under test (DUT), and cooling mechanisms to dissipate heat generated during the testing process. The testing of HV components also requires rigorous project management to help ensure the thoroughness and accuracy of testing. On average, compliance testing of an individual HV component can involve as many as 25 different tests on multiple samples of a single component. The sheer scope of testing activities must therefore be carefully planned and closely managed to provide the accurate data that is required for an objective assessment of critical performance considerations.
Finally, the testing of HV components necessitates in-depth expertise in advanced components. As few component manufacturers currently have the requisite test competency, they are either faced with developing that expertise in-house or identifying third parties that are sufficiently experienced.
HV testing
The HV testing scheme comprises testing of HV components under simulated environmental conditions in accordance with standards including LV123, LV124, LV148, and further customer-specific standards. The LV standards were developed jointly by several German car manufacturers, including Audi, BMW, Daimler, Porsche and Volkswagen, and published by the VDA. Most global OEMs have now derived their own version of the standard for internal use and for their suppliers.
The tests provide proof that the high- voltage components are able to function efficiently and comply with ultra-strict safety requirements. They include: Temperature testing: Exposure of HV
www.cieonline.co.uk
Electrical testing: These tests include insulation resistance measurement, sparkover voltage tests, and temperature stress tests.
EMC testing: Ensures that components in electric vehicles do not emit electromagnetic interference and are themselves resistant to external electromagnetic influences. This includes testing for interference emission, interference resistance, and dielectric strength.
Moving up a gear to HPT EV technology development is evolving at a rapid pace, with the introduction of intelligent components communicating with each other and the environment, alongside new standards, and requirements within the automotive industry. Increased testing options and flexibility are therefore required for those intelligent and interconnected components to test against multiple scenarios. Our customers are also demanding automated test environments that allow the simulation of vehicle communications.
In such a high-performance testing approach, an automation system sits at the heart of the testing set-up, communicating with other components and simulating different test situations to which the test component is exposed. At the same time, a cooling system is required as the system under test will experience significant heating during the simulation. Depending on the operation mode, flexible power supplies can be embedded, including several sources and sinks. This will enable control and measurement data acquisition to be carried out in real-time so that the behaviour of the systems under test can be observed in a live environment with actual data. Due to this increased flexibility in HPT systems, individual test conditions and operation modes can be implemented.
www.tuvsud.com/uk Components in Electronics February 2025 15
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