Electric & Hybrid Vehicle Technology - July 2021
Testing for success (Dytran)
2021-07-21 03:50:28
Designing and developing high-performing electric and hybrid vehicles requires rigorous testing and validation
Automotive manufacturers must conduct comprehensive evaluations on vehicle components to determine their long-term durability and performance characteristics. While sharing some of the same engineering demands as traditional gas-powered vehicles, electric and hybrid vehicles have their own unique set of testing requirements. Dytran designs and manufactures accelerometers that automotive engineers can rely on to help them test for success.
Electric and hybrid vehicle testing often involves a greater risk of unreliable data due to interference from electrical fields. Possible NVH problems can arise due to high frequency switching and transients on the vehicle powertrain. Dytran offers a wide variety of electrically isolated accelerometers that reduce the impact of the noise generated by strong electrical fields, allowing for more accurate measurements
The ultra-miniature 3133B Series of triaxial accelerometers provides electric vehicle manufacturers an integral anodized aluminum cup that provides case ground isolation to eliminate structure-borne ground loop interference. The small, hermetically sealed sensors are designed to avoid mass loading the test article, replicating the natural motion of lightweight structures with greater fidelity.They can also be used to evaluate, improve and smooth rotating components and assemblies to eliminate unwanted oscillations/ imbalances or gear mesh noise that can affect the vehicle.
Dytran’s Model 3224B is a miniature, teardrop-style single axis IEPE accelerometer that has a hard anodized aluminum cup for case ground isolation. This innovative adhesive mount accelerometer series can be used in test environments up to 300°F. Model 3224B sensors are used to help identify sources of rotation-induced whine, motor noise and structureborne noise.
For applications requiring higher sensitivities, its 3055D Series features base isolation and a variety of sensitivities and full-scale ranges. The 3055D Series has a ceramic shear sensing element packaged in a durable, hermetically sealed titanium housing that withstands the harshest testing environments inside or outside the lab. This series is characterized by a very low signal-to- noise ratio amplifier and high resonant frequencies (> 25 kHz). Dytran also recently expanded this series to include new models with an extended operating temperature range of up to 325°F (163°C).
For electric vehicle engineers it is also important to understand how vehicle components will react to extreme temperatures. Vehicle manufacturers now utilize 3316 Series sensors to test the performance characteristics of batteries at high temperatures.
These miniature charge mode accelerometers can reliably operate in temperatures up to 1,000°F (538°C) using Dytran’s patented Silver Window technology. This technology replenishes oxygen to the sensor crystal while maintaining the hermetic seal, assuring continued high temperature operation with no loss of insulation resistance due to oxygen deprivation.
Dytran also offers variable capacitance (VC) MEMS accelerometers that are designed for measuring steady-state linear acceleration and low frequency dynamic events. These sensors are used in transportation environment replication/simulation, modal and structural analysis, suspension development, NVH testing and ride quality. The 7509 Series incorporates a sturdy anodized aluminum housing for reliable operation in wet environments. This series incorporates internal MEMS sensing elements and is used for measuring low frequency response down to 0 Hz. The 7509 Series features high sensitivity at low frequencies and can operate over a broad temperature range.
As the automotive industry evolves and shifts more focus to electric vehicles, innovative and advanced sensing solutions will help keep engineers at the forefront of technological development.
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