2011 IEEE International Symposium on Electromagnetic CompatibilityFR-PM-2

August 14-19, 2011 – Long Beach, CA

This presentation is a joint project by Jastech EMC Consulting and TÜVSÜD America that looks at EMC testing of Energy Storage Systems (ESS)for Electric (EV) and Hybrid Electric Vehicles (HEV). The focus is to sharethe challenges and flexibility that a test facility needs to address in order toaccommodate OEM approved Test Plans and development testing.

The presentation is presented in 2 parts:

1. “Defining the Test Methodology using System Engineering”, presentedby James Muccioli from Jastech EMC Consulting, will discuss thedifferent modules and functionality being integrated into the EnergyStorage Systems using a System Engineering methodology ofindentifying requirements and defining EMC objectives.

2. “Test Laboratory Practical Implementation”, presented by DaleSanders from Jastech EMC Consulting, will discuss the “how to”and flexible capability required that an automotive EMC Lab willneed to have to test ESS Units. Several examples will be shown ofhow TÜV SÜD America addresses the physical size issues as wellas equipment/facility required investments.

EMC test facilities want well defined test standards andtest plans to follow for verification/validation testing (DV &PV).

Developing Standards, test methodologies or set-upcriteria should be:

Done through work on standards committeesDefined during the design/development stage of a product.Supported by test facility in developmental testingDocumented in DV/PV test planNOT interpreted or defined during verification/validation testing

In the past, component/module could typically get awaywith minimal instructions in a test plan or no test plan atall because:

Product is relatively simple and stand-aloneGenerally have a “small” physical sizeFit well within defined test parameters of a standard

ESS are complex SYSTEMS that challenge typical EMCtest facility accommodations and standardsrequirements.

For a quick comparison of typical component vs. ESS:

Normal automotive component■ Size is typically under 1 cu. ft. (1’x1’x1’)■ Weight under 10 lbs■ Set-up time for testing 2-4 hours

ESS ■ Size can range from 8 cu. ft. (2’x4’x1’) to 64 cu. ft. (4’x8’x2’)■ Weight can range from 700 lbs to over 2500 lbs■ Set-up time is double or more than normal automotive DUTs.

What are the big-picture ISSUES for a testfacility to test ESS?

What are the considerations to apply Standardswritten for small components to large ESS?

How do test facilities maintain integrity & complianceto Standards and Accreditation bodies?

What flexibility is required in order to accommodateESS testing?

ESS are bigger and heavier than typical Automotive components.

Testing now involve high voltage (300-600 V) and high current (100-300 Amps)

Regulations, Standards & ReferencesOccupational Health and Safety Administration (OSHA) Regulations: Subpart S-Electrical 29 CFR 1910.331-.335National Fire Protection Association (NFPA) 70E: Standard for Electrical Safety in the WorkplaceArgonne National Laboratory: Practical Application of Electrical Safety PracticesSandia National Laboratories: Advanced Technology Development Program for Lithium-Ion BatteriesOklahoma State University: Electrical Safety

Procedures & PoliciesTÜV Safety Procedures (Safe Working Practices)■ Boundary Limits■ PPE – Equipment & Tools■ Lockout/Tagout■ Energized Circuits, De-energized Circuits, Re-energizing CircuitsPersonnel Training■ Qualified Persons – One who has received training in and has demonstrated skills and

knowledge in the construction and operation of electric equipment and installations and the hazards involved.

■ Unqualified Persons – have only limited training in safe work practices.Contractors, Customers & VisitorsHazard Identification and Response Procedures

EMC Testing of ESS is going to require investment and modification.

Typical 3 meter modularchambers are not designed tosupport localized weight thatESS can present. Forexample:

Raise reflective ground plane (6 or12 inch): 125 lbs./sq. ft. distributedPoint rating should not be over 200lbs.

TÜV Solution - ESS testing isdone in chamber with weldedsteel floor that is directly on topof concrete slab.

Can chamber floor handle theweight of ESS and equipmentneeded to lift?

Welded steel floor on concrete

Raised modular floor

Typical 3 meter modular ALSEchambers are not designed toallow direct forklift access.NOTE: lip located on the floorused to secure doors needs tobe protected from damage.

TÜV SolutionDouble doors on chamber.Employ forklift that have ability toreach and traverse in chamber.Custom built ramps to allow forkliftin chamber.

How to get access inside thechamber for lifting equipment?

TÜV Solution – Chamber isplumbed for water, air &hydraulic fluid.

ESS units may requirecompressed air or circulatedliquid to cool ESS and/or loads.What options are available thatmaintain shield integrity of theChamber?

Outside Chamber

Inside Chamber

In order to accommodateESS size and comply withGround Plane dimensionalcriteria, the Ground Plane willneed to grow significantlyfrom typical size.

In order for tables to supportthe weight of ESS, tables willneed to be structurallyredesigned.

TÜV Solution – custom builttables with large GroundPlanes that can handle weightrequirements of ESS.

Ground Plane & supporttables in Chamber

Chamber orientation mustgive consideration to:

Growth of GND planeDimensional constraints calledout in StandardsAccess for lifting/movingequipment

TÜV Solution – Chamberand moving equipmentallow for reconfiguration ofchamber orientation.

Can the orientation of thechamber be modified toaccommodate larger GNDPlane and/or betteraccess?

Linear Power SupplyVoltage requirementsCurrent requirements

Chamber FiltersRated Current

External charging systemsAdditional considerations

ESS Battery Cell Operating Levelsneed definedNeed charging procedureCharging downtime affects testthrough-put timing.Shielded High Voltage Cables

What charging & power supplyrequirements are needed tosupport ESS testing?

ABC 150/DCU Power Processing System

Bulkhead filter rating for ChamberFacility electrical supplyCabling to test set-upProgramming & Monitoring

Passive ResistorPower ratingCoolingRepresentative impedance

Actual vehicle LoadInverterMotors

LISN

What Loads & ArtificialNetworks are now neededfor High Voltage?

ABC 150/DCU PowerProcessing System

Passive Resistor Bank

Power Inverter from vehicle

Fiber optic lines are neededfor:

Video equipmentAudio equipmentAnalog signalsCANBus (multiple busses?)LINBus (multiple busses?)

Fiber optic convertersESS require more monitoringaccommodations.

What monitoring & supportequipment will be needed?

Meeting requirements for Automotive Standards

An ESS is generally tested to the following International Automotive EMC Standards or approved deviation thereof:

CISPR 25Radiated Emissions (RE)Conducted Emissions (CE)■ Current Method■ Voltage Method

ISO 10605Electro-Static Discharge (ESD)■ Powered■ Handling (non-powered)

ISO 7637:2,3(7637:2) Transient Conduction for supply lines■ Transient Emissions■ Transient Immunity (7637:3) Transient Transmission for non-supply lines■ Capacitive Coupling Clamp (CCC)■ Direct Capacitive Coupling (DCC)■ Inductive Coupling Clamp (ICC)

ISO 11452:2,4(11452:2) Radiated Immunity (RI)(11452:4) Bulk Current Injection (BCI)

Note: Examples shown in thenext few slides have deviationsin set-ups due to physicalgeometries which have beenapproved by customers.

Shown is monopole set-up, additional set-ups include biconical, Log & Horn

Shown is Horn set-up

Additional ConsiderationsElectrical Testing Over TemperatureCustomer monitoring equipment and system settings

ConclusionEfficient testing throughput is needed for test facility scheduling and economics.Customer needs to work hand-in-hand with test lab for test plan development.■ Safety■ Moving & handling■ Facility & test equipment requirements ■ Details of set-up and functionality (engineering support)■ Customer needs to specify and sign-off on deviations due

to physical size and system complexity

QUESTIONS ???

For more information or to contact us:

http://www.Jastech-EMC.com, Phone (248) 876-4810

http://www.TUVAmerica.com, Phone (734) 455-4841