BENDER Group

Dipl.-Ing. W. Bender GmbH & Co. KG

Londorfer Strae 65 35305 Grnberg
+49 6401 807-0 +49 6401 807-259
issued 02.12.2009 Authors: Holger Potdevin
Gerald Scheffels
New measurement method
increases safety
Reliably prevents accidents from electric shock in electric
and hybrid vehicles
W H I T E P A P E R
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 2
New measurement method
increases safety
Reliably prevents accidents from electric shock in electric
and hybrid vehicles
Contents
Page
New measurement method increases safety 3
New risks must be safeguarded against 4
Developing a new measurement method 5
Specially for automotive applications 5
Versatile integration into the drive architecture 6
Safety by using two different measurement methods 6
Formula 1 experience as a good basis for large-scale use 7
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 3
New measurement method
increases safety
Reliably prevents accidents from electric shock in electric
and hybrid vehicles
New measurement method increases safety
prevents accidents from electric shock in electric
and hybrid vehicles
The increased use of hybrid drives and electrical energy storage devices in vehicles
increases the risk of dangerous accidents from electric shock. Insulation faults can result
in high touch voltages (as with Formula 1) and this puts people at risk. For this reason,
Formula 1 is already using a new type of insulation monitoring system which is now also
available for use in the automotive industry.
The crucial advantage of the new iso-F1 over other measurement methods is that it is
able to modulate the active measuring voltage and can adapt to the conditions of the
electrical system. Where measuring devices previously used in electric and hybrid vehicles
were only capable of passive measurement up to the converter, this compact 50 g mea-
suring system can monitor the level of insulation of the entire high-voltage system actively
from the battery to the drive motor, including the active converter. It can also be used
under extreme temperature conditions (- 46C to 125C), withstands extreme shocks and
vibrations and meets the stringent requirements concerning electromagnetic compatibility
and high-voltage strength. It therefore provides reliable continuous vehicle monitoring
during operation and in any driving situation.
While iso-F1 was initially developed as a
customer- and application-specific module
for monitoring the electrical KERS system
of Formula 1 vehicles, it can be used in all
systems with operating voltages up to 800
VDC and is homologated by the FIA.
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 4
New measurement method increases safety prevents
accidents from electric shock in electric and hybrid
vehicles
The increased use of hybrid drives and electrical energy storage systems has
created a new hazard insulation faults can lead to high electrical touch voltages
on the vehicle body. There has already been one accident from an electric shock
from a Formula 1 vehicle. Formula 1 is therefore using a new insulation monitoring
system for this season. And this system is now also available to the automotive
industry.
Even though the way forward for future drive engineering is still unclear, there are some
trends on which most experts can agree. These trends also include increasing the use
of electric drives the internal combustion engine is not expected to be replaced com-
pletely in medium-term. This applies to vehicles which run on electrical power alone and
are expected to have a significantly increased range during the next years as the battery
technology is improved. It is also true (and even more so in the short term) for supporting
drives for short journeys which also have a storage function. Almost all automotive manu-
facturers are working on this type of concept.
Electrification of the vehicle drive
This development has meant that the vehicle drive is electrified and, although this
increases the efficiency of the drive system, it also introduces new risks. These risks
should be reliably prevented perhaps an altogether new territory in technology for the
vehicle engineer. In general, however, such safety systems are well-known and tried
and tested in stationary electrical engineering even though additional requirements
have to be catered for in vehicle technology.
The risks are well-known
The risks which have to be prevented were demonstrated by an accident which took
place on the Jerez Formula 1 race track in Spain in July 2008, which was much discussed
among hybrid drive developers. In the pit lane, a mechanic touched a Formula 1 vehicle
which was fitted with a Kinetic Energy Recovery System (KERS) and suffered an electric
shock.
This danger also exists with other cars which have electric or hybrid drives because
the steel bodies of utility vehicles and passenger cars are conductive just as the carbon
fibre composite structures are on racing cars.
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 5
Quick response development of a new measurement method
After this accident, the Formula 1 racing stables responded quickly. From the beginning of
the 2009 season, they have been using a new insulation monitor from Bender which was
developed especially to meet the requirements of mobile drive and electric technology.
The device, designated A-ISOMETER iso-F1, differs from the usual measurement methods
in that it is able to modulate the active measuring voltage and adapt it to the conditions
of the electrical system. This compact measurement system, which is accommodated
on a pcb and only weighs 50 g, can therefore monitor the entire high voltage system from
the battery to the drive motor, including the active frequency converter. The monitoring
system is effective during the entire period of operation and in any driving situation. The
fundamental difference between this and other systems is that the measurement is active
and takes into account the entire system up to the motor, including the converter, while
the measuring devices previously used on electric and hybrid vehicles were only passive
and stopped at the converter.
Developed for automotive applications
The device also records symmetrical faults. Since the internal resistance is very high,1 M,
the measuring currents generated are only very small, in the A range. High frequencies
from converters do not interfere with the device since it is fitted with suitable filters in the
measurement coupling. The measurement results are even immune to large voltage fluc-
tuations in the high voltage system. The same also applies to very frequent sudden load
changes and the associated "low-frequency" voltage fluctuations
in the DC part of the drive.
The iso-F1 measuring device can therefore cope with the highly
dynamic conditions which prevail in automotive hybrid and
electric drives. However, if the measurement is disturbed
by indefinite factors, then this is detected and rejected from
the measurement taking place. A periodic device self test
provides the user with additional safety to ensure that
the device actually responds to situations which are
dangerous.
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 6
Basis for individual projects
The module was initially developed as a customer- and application-specific device for
monitoring the electrical KERS system of Formula 1 cars. It can be used in all systems
with operating voltages up to 800 VDC and is homologated by the FIA.
The device which Bender is now offering to the automotive industry was conceived as a
basic device or a basis for development for individual OEM projects. The choice of module
corresponds to the standards required by the automotive industry and satisfies the strictest
requirements in terms of electromagnetic compatibility (EMC) and high voltage strength.
The same applies to the shock and vibration resistance. The device is suitable for ambient
temperatures ranging from -46C to 105/125C and therefore also fulfils the temperature
requirements of the automotive industry. All the components are installed on a pcb and
the sequences which are used to create the conditions for cost-effective manufacture
and testing are highly automated and of the highest standard.
Versatile integration into the drive architecture
The device has optocouplers for outputs which output the signals for values below the
response value and for device faults. The measured value is provided as a universally
readable PWM signal via another optocoupler. Thus, the iso-F1 device can be easily
integrated into the drive and control architecture of the vehicle concerned. The 10-36 VDC
version and high-voltage versions up to 1000 VDC will also be available in the short term.
Safety by using two different measurement methods
The high level of safety offered by the iso-F1 measuring device is guaranteed by using
two different measurement procedures. In one case, the device uses a well-known but
improved method for determining the real leakage resistances. Another method is used to
determine both the real and the capacitive leakage resistance. This is of particular interest
at higher converter frequencies since the leakage currents in the AC range are largely
determined by the capacitive component. Here, it is possible to cause the battery to be
immediately disconnected in order to meet the
requirements for the safety of individuals and
reliably prevent dangerous touch voltages
occurring due to insulation faults.
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 7
Formula 1 experience as a good basis for large-scale use
Passing the endurance test of Formula 1 racing cars is a good basis for using the iso-F1
for mass production applications in road vehicles. This is not only true for passenger
vehicles with electric drives and hybrid support. Electric drives will also be increasingly
accepted generally in mobile machine tools and lorries. In this case, the development
will focus on vehicles which start and stop
frequently such as passenger vehicles,
dust bin lorries, wheeled loaders and fork-
lift trucks. The iso-F1 system can also be
adapted to the conditions associated with
the drives and control architectures of
these vehicles. Bender already has expe-
rience with monitoring the insulation of
forklift trucks and buses with Diesel elec-
tric drives etc. and has also developed
a design for these applications.
Wide experience in monitoring electrical systems
While developing the new measuring device for monitoring the insulation of electrically
powered vehicles, Bender was able to use its extensive experience in the special field of
safety engineering. The company is a market leader in systems for monitoring electrical
safety. These are used all over the world in all industries for monitoring unearthed and
earthed systems. The product range also includes systems for industry-specific special
applications such as power stations, industrial plants, the automation industry, hospitals,
the mining industry, ships, submarines and railway engineering. In the electrical and hybrid
drives of road vehicles, Bender has identified a rapidly growing market and is therefore
investing in research and development as well as expanding the production capacities
for monitoring systems for motive applications.
Dipl.-Ing. W. Bender GmbH & Co. KG, New measurement method increases safety, issued 02.12.2009 8
Authors
Mr Gerald Scheffels, specialist journalist
Mr Holger Potdevin,
Key Account Manager iso-F1
Dipl.- Ing. W. Bender GmbH & Co.KG
Londorfer Str. 65 35301 GRUENBERG / GERMANY
Tel: +49 6401 807 275 Fax: +49 6401 807 279
E-mail: holger.potdevin@bender-de.com
http:\\www.bender-de.com
Source of information
Dipl.-Ing. W. Bender GmbH & Co. KG
The Bender company group has its head office in Grnberg in the German state of Hessen
and is a market leader in monitoring systems for electrical safety. For more than six decades,
it has been producing top-quality products which have an outstanding reputation in all
industries across the world. Bender products are used for the measurement and moni-
toring of earthed and unearthed systems in more than sixty countries. As well as offering
a wide product range, we are also known among experts as a supplier of sector-specific
applications, for hospitals, mining, the automation industry and chemical industry, machine
tool manufacture, ships and submarines, railway systems and wind and solar power
installations etc. With the A-ISOMETER iso-F1, the company has succeeded in developing
another special application for the growing area of electric and hybrid vehicles.
The Power in Electrical Safety