Open Doors Spain and Portugal 2024

ELECTRIC DRIVETRAIN TESTING

USING OSCILLOSCOPES

Victor Medina
Application Engineer - Oscilloscopes
 CONTENT

1. Market & Technology

Trends
2. Challenges & Benefits
3. eDrivetrain measurements
using Oscilloscopes
4. Technology and testing
summary

2
 CONTENT

1. Market & Technology

Trends
2. Challenges & Benefits
3. eDrivetrain measurements
using Oscilloscopes
4. Technology and testing
summary

3
MARKET & TECHNOLOGY TRENDS
► By 2035 most industrial countries will ban the
sales of new combustion engine vehicles.

► Further improvement of electric vehicle Source: Global EV Outlook 2023, International Energy Agency

charging time, driving range and reduction of

system costs and weight is required. Source: Denso Automotive Ethernet Congress 2022

► Car manufacturers heavily invest in new

technologies and models.

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MARKET & TECHNOLOGY TRENDS
► Charging times shall be reduced with battery
voltages going up to 800V and above.

► Driving range shall further be improved by

maximization of electrical power efficiency.

► New fast switching wide bandgap

technologies such as Silicon Carbide (SiC)
shall lead to reduction of power losses;
higher power is manageable.

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MARKET & TECHNOLOGY TRENDS
EV POWER ELECTRONICS MARKET DEVELOPMENT

+21%

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 CONTENT

1. Market & Technology

Trends
2. Challenges & Benefits
3. eDrivetrain measurements
using Oscilloscopes
4. Technology and testing
summary

7
CHALLENGES AND BENEFITS
Major power electronics system components of an electric drivetrain

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TECHNOLOGY TRENDS
EV TRACTION INVERTER
► Fast switching Silicon Carbide modules
improve power efficiency
► Integration of several modules (e.g. DC/DC +
DC/AC) decreases size and weight

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CHALLENGES
TEST & MEASUREMENT
Efficiency and endurance Signal and transient
Verification analysis
► Quantify power losses and achieved ► Verify switching & conduction
inverter efficiency (efficiency map) losses
► Efficiency verification of converters ► Verifying reliable fast silicon
► Verify inverter efficiency symmetry in carbide technologies
both driving and recuperating ► Verify and optimize control signals
operation (bi-directional operation) for two/three-level traction inverter
► Ensure maximum efficiency at higher ► Investigate potential sources to
switching frequencies and multiple improve transient behavior
output voltages ► Check high-frequency interference
on surrounding low-voltage
electronics

Precise power- and ultra-fast signal analysis prove and verify the performance

10 Rohde & Schwarz Electric drivetrain testing

 CONTENT

1. Market & Technology

Trends
2. Challenges & Benefits
3. eDrivetrain measurements
using Oscilloscopes
4. Technology and testing
summary

11
THE ELECTRIC DRIVETRAIN

Rohde & Schwarz 12.04.2024 Electric drivetrain measurements using oscilloscopes

DESGIN CHALLENGES
CONVERTER + INVERTER
► Minimize switching losses and maximize thermal efficiency with proper
design of inverter/converter electronic

► Verify stability under different loads and environmental conditions

► Achieve EMI compliance when using new wide-bandgap materials

− High switching frequencies
− Steep rising edges

► Ensure the integrity and timings of power rails meet design rules

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 THE NEXT MXO FAMILY: R&S®MXO 5
LAUNCH: 31 OCT, 2023
Rohde & Schwarz
 EVOLVED FOR MORE CHALLENGES

8 x analogue channels 4 x FFT spectrum analysis 4 x protocol, 16 x logic channels

4.5 Mil wfms per seconds 45 kFFT per seconds Dedicated logic channels
500 Mpoints per channels Time collated FFT with deep memory Simultaneous protocol decode
18-bit HD resolution

Rohde & Schwarz

 MXO 5
First 5000 class with
VESA mount
MXO5-Z7
Dual ARB Gen
100 MHz

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 MXO 5
25 dBA 1 meter from instrument
First 5000 class with
It is whisper quiet… VESA mount

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What’s new?

WORLD’S FASTEST PERFORMANCE … EVOLVED

36
72
Custom fab million
Gates
200
400 Gb/s
Designed

18 Million
4.5
Acquisition/s
Acquisition/s
Realtimecapture
Realtime capturerate
rate

MSO and
waveform generation
18-bit 0.0001
Vertical Trigger
Resolution Sensitivity
System Digital trigger
400
500 Mpts
Architecture Architecture Hardware backend processing Pixelizer Standard
Waveforms, Spectrum, Math, Measurement,, Mask, Memory
Zone Trigger, Serial bus...

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KEY USP MXO 5

> 4.5 Million wfms / sec Instantly see MORE signal detail

12 -bit ADC 18-bit HD MORE resolution on all sample rate

500 Mpts memory /ch Capture even MORE time

Digital trigger Trigger with MORE resolution

> 45 k FFT / sec FASTER FFTs with instant detail

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OSCILLOSCOPE APPROACH
► High-frequency analysis
− PWM waveforms
− Motor commutation signals
► Real-time analysis
− Diagnose issues and make adjustments on the fly
► Ability to capture transients
− Voltage spikes
− Noise
► Ability to analyze individual components
− Motor
− Inverter
− Power supply
− Transistors

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ANALYSIS TOOLS
► Oscilloscopes include different automated
measurements for power analysis:
− Power quality
− Input harmonics
− Inrush currents
− Efficiency
− Power up and power down sequences
− Switching losses

► It does not offer the same precision as a power

analyzer, but it is a good alternative for an
initial approach to the EUT

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ELECTRIC DRIVETRAIN
ANALYZE INVERTER - MOTOR SIGNALS
Electric Drive Train
Inverter drives performance,
switching behaviour,
transistor gate timing

More channels to observe 3-phase

inverter with current and voltage

Longer record length to capture

slower events behavior

Spectrum analysis on motor

characteristics signature

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ELECTRIC DRIVETRAIN
ANALYZE INVERTER - MOTOR SIGNALS
► The switching behavior of the inverter in a motor drive system can
have significant impact on the motor.
► Negative effects in the performance: Reduced efficiency, increased Motor
temperature, acoustic noise, reduced torque and EMI.

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ELECTRIC DRIVETRAIN
ANALYZE INVERTER - SWITCHING BEHAVIOR
► Analyzing the switching behavior of an inverter in an electric vehicle is crucial for improving
efficiency, reducing EMI noise, preventing damage and enhancing safety.
► Voltage and current probes must be selected accordingly.

Gate driver

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ELECTRIC DRIVETRAIN
ANALYZE INVERTER - SWITCHING BEHAVIOR
► As a rule of thumb, it should be checked:
✓ VGS and VDS
✓ Rise times and fall times (10/90 or
20/80)
✓ Overshoot, ringing
✓ General timing of high- and low-side
switch (synchronous converter)
✓ Robustness test
✓ Relation between the three phases of
the inverter

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ELECTRIC DRIVETRAIN
ANALYZE INVERTER - QUANTIFY LOSSES
► Semiconductors operation generate losses ► Switching losses to be evaluated
− Conduction losses − Turn on losses
− Switching losses − Turn off losses
− Reverse recovery losses
► Losses are important for cooling system

Drain
IDS +

VDS
Gate

-
Source
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ON BOARD CHARGER PFC

DC/DC DC/AC

Rohde & Schwarz 12.04.2024 Electric drivetrain measurements using oscilloscopes

Typical measurement scenarios

INPUT AND OUTPUT SIGNALS

Input Output
- Input harmonics AC-DC / DC-DC - Voltage ripple
- Power quality Converter - Load transient
- Inrush current - Load regulation

Efficiency, power-up and power-down sequences

Rohde & Schwarz 12.04.2024 Electric drivetrain measurements using oscilloscopes
ELECTRIC DRIVETRAIN
INPUT POWER ANALYSIS MADE EASY (MXO5-K31)

Harmonic Analysis Power Quality

► In line with EN 61000-3-2 classes A, B, C, D, ► Easily determine active, reactive and apparent
MIL-STD-1399 and RTCA DO-160 power, crest factor and phase angle
► Support 3 simultaneous measurements ► Support 3 simultaneous measurements

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ELECTRIC DRIVETRAIN
ANALYZE DC-DC CONVERTERS – OUTPUT VOLTAGE RIPPLE
Vout
► PARD = Periodic and Random Deviation PARD

► Spurious AC components create ripple

DC Output
− Periodic: Ripple
− Switching Noise
− Load Step (Large) Examples
− LC Tank
Rail Tolerance Need to
− Random: Noise
Value measure
3.3 V 1% 33 mVpp
► Specified over a bandwidth
1.8 V 2% 36 mVpp
− Typically 20 Hz to 20 MHz 1.2 V 2% 24 mVpp
− Careful, below 20 Hz is Output Drift 1V 1% 10 mVpp

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ELECTRIC DRIVETRAIN
ANALYZE DC-DC CONVERTERS – OUTPUT LOAD TRANSIENT
► Sudden change in the output load current caused by a change in the load resistance or a change in the
output voltage demand.
► Response depends highly on control loop

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ELECTRIC DRIVETRAIN
PROTOCOL ANALYSIS
► CAN/CAN FD/CAN XL
► Motor control
► BMS
► Regenerative braking
► Safety systems

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ELECTRIC DRIVETRAIN
EMI DEBUGGING

► Standard fast spectrum with 45k FFTs/second

► Support log-log scale and dBuV display of unit

HZ-17 Near Field Probes support 30MHz to 3GHz
► Peaklist, min/max-hold and intensity grading HZ-16 Amplified extend HZ-17 down to 9kHz

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Our Solutions

TESTING SOLUTIONS FOR E-DRIVE TRAIN

MXO5 (8 channel scope) Impedance Analyzer to characterize the

► Update rate exceeding 4.5 million wfms/s
► Industry-best signal integrity with 12-bit ADC and
18-bit architecture, 500µV/Div
► Memory of 500 Mpoints per channel
► Digital triggering technology
► Up to 4 different FFT’s
DC link / bulk capacitor
► Wide impedance range (1mΩ to 1TΩ)
► Low frequency operation (1mHz up to 5MHz)
► Fastest measurement speeds in LCR Mode
(10μs at 1MHz)
► LabOne® software & API suites

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 CONTENT

1. Business Trends
2. Technology Trends
3. Test Solutions
4. Technology and testing
summary

35
ELECTRIC DRIVETRAIN
TECHNOLOGY AND TESTING SUMMARY
► Success of electric vehicles depends on 3 major factors:
Affordability, Charging Time and Range
► Battery voltages go up to 800V and above to achieve faster charging.

► Fast switching Silicon Carbide modules improve power efficiency which in

the end has an influence on the drivetrain
► In the design phase, a test strategy based on characterizing, debugging
and optimizing using an oscilloscope enables losses to be identified and
efficiency to be maximized.
► R&S offers a wide range of suitable test solutions (frequency and time
domain),
if required even together with selected reliable partners.

36 Rohde & Schwarz Electric drivetrain testing