Training System Christiani HV Trainer
Electric Drives and HV Systems in Vehicles

Item No.: 45861

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Functional model of e-drives and HV systems in motor vehicles

The functional model E-drives and HV systems in motor vehicles consists of a drive module and a power supply and control module. The HV system operates with an operating voltage of 96 volts. A complete power supply unit with electronic battery management (BMS), an integrated charger for the HV battery, a control unit with motor management system, all necessary safety components, Mennekes charging connection (type 2) are built on. The HV system can be enabled either via a service disconnect in the 12 V circuit or via a service disconnect in the HV circuit (in the HV battery). In addition, the training system has a rescue disconnection point to represent the disconnection of an accident-damaged vehicle. The HV battery, with 96 volts nominal voltage, is equipped with 32 LiFePO4 / 40 Ah cells. The battery management system has a Bluetooth interface. The status (voltage, temperature, balancing rate during the charging process) of each individual battery cell can be displayed via an associated app (Android).

Drive module

The drive module consists of a complete, vehicle-electric drive train with 1.6 kW asynchronous machine, control unit with controller (E-Car-Box), DC/DC converter, fuses, high-voltage main contactor and control software with multi-stage adjustable recuperation mode for displaying energy recovery as well as a hydraulic brake for load simulation (driving uphill).

E-Car-Box

The E-Car-Box is the heart of the drive. All important components for controlling the motor are installed in it in a space-saving, safe and EMC-compliant manner and wired according to the highest safety standards. In addition to the air-cooled Curtis controller for controlling the motor, it also contains the main contactor, a DC/DC converter and all the necessary high- and low-voltage fuses.

Battery Management System (BMS)

The battery management system is used to monitor the lithium iron phosphate battery cells installed in the HV-Trainer and to protect them from over- and undervoltage during the charging process and while driving. The central control unit communicates via CAN interface with the connected charger and the motor controller. The battery management system has a Bluetooth module for communication between the BMS and a display instrument such as a smartphone, tablet or a Bluetooth-enabled Windows PC. This module can be used to monitor the state of charge of the batteries and various other parameters. Software for Windows and an Android app are available for download.

Feasible work on the HV training system:

Voltage disconnection with service disconnect high-voltage circuit
Voltage disconnection with service disconnect low-voltage circuit
Voltage disconnection with rescue disconnection point
Determine absence of voltage
Secure against reconnection
Measuring the DC link capacitor charge and discharge curve
Locate defective battery cells by measurement
Replacing battery modules
Check connector between cells for contact resistance
Function test of contactors
Checking the safety line (interlock circuit)
Checking the insulation monitor
Check motor encoder and motor temperature sensor
Display load simulation (uphill drive) visibly and measurably
Programming of the HV controller with hand-held programmer or PC interface

Measurement possibilities:

Phase voltage and phase signal (U, V, W) to the e-motor
12 V on-board voltage
HV battery voltage
Potential equalisation measurement
Insulation resistance measurement
Insulation monitor signal (PWM signal)
Inverter intermediate circuit voltage
CP signal at charging socket (communication with charging station)
Safety line (interlock circuit and interlock signal voltage)
Input DC/DC converter (plus and minus)
Output DC/DC converter (plus and minus)
Temperature and voltage of a single battery cell (via BMS)
Current sensor signal
E-motor speed and temperature sensor signal

Fault circuits

The functional model has an integrated fault circuit with which 10 faults in the power supply module and 16 faults in the drive module can be switched. The fault circuit is controlled with a specially developed app (Android) via Bluetooth with a tablet or smartphone (included in the scope of delivery).

Fault circuit in the drive module:

DC link capacitor residual energy discharge does not work
intermediate circuit capacitor residual energy discharge too slow
coil main contactor in drive module interrupted
main HV contactor in drive module defective
main HV contactor in drive module stuck/welded together
DC/DC converter does not switch on
motor temperature sensor defective
Motor encoder phase line interrupted
CAN bus disturbed
Motor phase (W) interrupted
insulation fault HV+ warning
Insulation fault HV+ alarm
Insulation fault HV- warning
Insulation fault HV- alarm
Insulation problem HV+
Insulation problem HV-

Fault circuit in the battery module:

insulation resistance below the warning threshold
insulation resistance below the alarm threshold
interlock service disconnect interrupted
overtemperature of a battery cell
interruption of the DC line of the charger
HV+ battery contactor does not close
HV+ battery contactor stuck/welded together
charging communication interrupted
AUX module supply HV+ line interrupted
cell module communication interrupted

More errors:
Fuse F3 (DC/DC converter) defective
Fuse F4 (battery+ Kl. 30) defective
Fuse F5 (drive module emergency stop) defective

Motor vehicle mechatronics technician
Motor vehicle mechatronics technician with focus on system and high-voltage technology

Observance of accident prevention regulations
Avoiding hazards when handling electrical current and hazardous substances
Selection of suitable and safe testing and measuring equipment
Handling and use of safety equipment
Application of manufacturer-specific test routines
Disconnecting high-voltage components, securing them against being switched on again, ensuring that they are voltage-free
Recognising the dangers posed by electrical storage devices (capacitors, high-voltage batteries).
Recognising the general laws of electrical engineering
Create system and block diagrams
Identifying the effects of electrical quantities on the human organism
Troubleshooting and interpreting the diagnosis of affected systems
Analysing the function and interaction of components, taking into account the exchange of information between the control units involved
Recognising system interrelationships with the aid of circuit and function diagrams
Analysing time-dependent variables and evaluating signal patterns
Applying knowledge of the laws of voltage generation (induction), rectification (one-way and multiway rectification), the electromotive principle and the storage of electrical energy
Assessing hazards during live measurements, deriving protective measures and checking the effectiveness of the electronic protective measures of the high-voltage system
Carrying out measurements under voltage (insulation, equipotential bonding and voltage drop measurements, battery cell voltages, temperature determination)
Functional testing of high-voltage systems (control signals of the electric motor during driving)
Assessing measured values and signals for plausibility and creating test reports
Planning the diagnosis and repair of the high-voltage system and its components