This article takes you to ISO 7637-4 testing._Century Wisdom (Suzhou) Testing Technology Co., Ltd

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This article takes you to ISO 7637-4 testing.

Release time:

2023-04-03 15:14

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In 2020, ISO issued the ISO7637-4 "Road Vehicles-Electrical Disturbances Caused by Conduction and Coupling-Part 4: Electrical Transient Conduction Along Shielded High-Voltage Power Lines", which specifies the test methods and procedures for the conduction electrical transient of shielded high-voltage power lines for equipment on passenger cars and commercial vehicles with power supply isolated from the body, and is applicable to all types of electrically independently driven road vehicles.

This standard defines pulse sine wave disturbance (waveform A) and low frequency sine wave disturbance (waveform B), which are respectively used for high frequency oscillation test and transient voltage test. All transient tests shall be performed between HV and HV-(line to line) and between HV and ground, HV-and ground (line to ground), respectively. The case where different types of transients generated by the switching of different devices appear on the high-voltage power line is considered.

　　1. Scope of application

This standard is an urgently needed standard for the test of high-voltage components in the automotive industry. It provides a standard basis for the conduction transient test of shielded high-voltage power lines for equipment on road vehicles (electrical system voltage is greater than 60 VDC and less than 1500 VDC), and fills the gap in the international standard for the conduction transient test of shielded high-voltage power lines for high-voltage components.

Suitable for all types of electrically independently driven road vehicles, such as pure electric vehicles (BEV), hybrid electric vehicles (HEV) or plug-in hybrid electric vehicles (PHEV).

　　2. What are the test items of ISO 7637-4

What are the differences between the electrical transient conduction test items of high-voltage power lines and low-voltage electrical components? By comparing the ISO 7637-4 standard, we found that the test items are similar to ISO 7637 -2/3, and the conductive electrical transient test of high-voltage power lines is also divided into transient emission and transient immunity tests:

Voltage transient emission along high-voltage power lines
Waveform A (pulse sine wave) immunity test
Waveform B (low frequency sine wave) immunity test

Next, we will introduce the test purpose, test principle, implementation scheme and layout requirements of the three test projects.

　　2.1 voltage transient emission

Pulsed sine wave disturbances on the high voltage power line are generated by the overshoot of the square wave signal, such as the interaction of the switching IGBT in the high voltage system with the parasitic capacitance and inductance of the motor system, the DC-DC converter and any other high voltage switching/commutation system. The pulsed sine wave disturbance on the high voltage power line can be common mode (line to ground (HV or/and HV-to ground)) or differential mode (line to line (HV-to HV-)).

Transient Emission Test Arrangement for Measurement of Voltage Ripple between HV and HV-on High Voltage Supply Lines

Testing Scheme of Century Huize (Suzhou) Testing Technology Co., Ltd.

The upper figure shows the test arrangement with measurements between HV and HV−. When measuring between HV and earth or between HV-and earth, the other terminal of the voltage probe shall be grounded.

By comparison, we can see that compared to ISO 7637-2, the standard uses a high-voltage LISN, and the high-voltage power line conduction transient emission measurement does not require an electronic/mechanical switch.

Voltage Transient Emission Test Arrangement Requirements on High Voltage Supply Lines

　　2.2 waveform A (pulse sine wave)

Due to the existence of distributed inductance and capacitance in the high-voltage system, the high-current fast switching of IGBT in the electric system will cause overshoot, and the DC-DC converter or other high-voltage switching or communication devices will also cause disturbance distortion on the high-voltage line. This disturbance signal will produce common mode and differential mode interference. Therefore, in the immunity test, the pulse A represents the ringing generated by the switching operation of the high-voltage semiconductor, and is used to simulate the high-frequency oscillation.

Test waveform

Test pulse A (sine wave pulse)

This is a pulse modulated signal. The frequency standard of sine wave is 1MHz, 2MHz, 5MHz and 10MHz, and the oscillation of each pulse package has 10 cycles. The repetition period of pulse is 200/100/50us;Un is the normal working voltage of DUT; Upp is the voltage peak-to-peak value of test pulse, and the specific value refers to the following test grade:

Parameters of test pulse A (pulse sine wave disturbance)

Pulse A differential mode immunity test: the output end of the power amplifier is connected to the balun (a three-port device), so that the output interference pulse forms a loop between the high-voltage positive line and the high-voltage negative line;

Pulse A common mode immunity test: The power amplifier output is directly connected to the positive or negative high-voltage artificial power supply network, so that the output interference pulse forms a loop between the high-voltage positive or negative line and the ground.

The block diagram of the test principle is as follows:

Transient Immunity Test Arrangement for Pulse A (Line to Line)

Pulse A Test Scheme of Century Huize (Suzhou) Testing Technology Co., Ltd. (Line to Line)

Transient Immunity Test Arrangement for Pulse A (Line to ground)

Pulse A Test Plan of Century Huize (Suzhou) Testing Technology Co., Ltd. (Line to ground)

Precautions for test arrangement:

1) The test uses a shielded high-voltage artificial network, and the DUT is connected to a high-voltage power supply through the artificial network.

2) Consistent with the vehicle application, the DUT should be placed on a ground plate.

3) If not otherwise specified, the DUT and all connecting wires between the artificial network and the DUT shall be non-conductive, low relative dielectric constant (r≤ 1.4) material placed (50±5)mm above the ground plate.

4) The length of the high-voltage power cord is recommended to be 500( 200/0)mm.

5) The DUT should be connected to the grounding plate through the original length and diameter wiring harness on the vehicle. If not specified otherwise in the test plan, the default length is (200±50)mm. The DC resistance of the earth connection shall not exceed 2.5 mΩ.

　　2.3 waveform B (low frequency sine wave)

Pulse B is a sine wave generated by the rotation of the electric drive motor and the grid harmonics, and most of the energy is present in the low frequency harmonic content, so it is used to measure the transient voltage immunity of the device under test, DUT.

Test pulse B (low frequency sine wave)

The above figure shows the parameters of pulse B, f1 and f2 represent different interference pulse frequencies; td represents dwell time; Upp represents the peak value of pulse amplitude; UN represents the normal working voltage (HV or HV-) of the tested article;

The specific values refer to the following test levels:

Test parameters of test pulse B (low frequency sine wave disturbance)

Transient tests shall be carried out between HV and HV-(line to line) and between HV and ground, HV-and ground (line to ground), respectively. The following figures show the pulse B differential mode (line to line) and common mode (between the positive pole of the high voltage line and the ground) test diagrams. It can be seen that the interference pulse is coupled to the test harness through the coupling device.

Differential mode test, coupled to the flow path of the differential mode interference on the wiring harness, flowing back between the positive and negative power lines.

Test pulse B (low frequency sine wave disturbance transient) immunity test arrangement (series injection "HV")

In the common mode test, the flow path of the common mode interference coupled to the wiring harness flows back between the positive or negative power supply line and the ground line.

Test pulse B (low frequency sine wave disturbance transient) immunity test arrangement (series injection "HV line to ground")

Connection diagram of test pulse B immunity test system-Century Huize (Suzhou) Testing Technology Co., Ltd.

Physical Connection Diagram of Test Pulse B Immunity Test-Century Huize (Suzhou) Testing Technology Co., Ltd.

Key points for test arrangement:

1) The test uses a shielded high-voltage artificial network, and the DUT is connected to a high-voltage power supply through the artificial network.

2) Consistent with the vehicle application, the DUT should be placed on a ground plate.

4) The length of the high-voltage power cord is recommended to be 500( 200/0)mm.

　　3. System composition

OK, the introduction about ISO 7637-4 test is finished, and then I will give you a recommend of the main instruments and equipment required by the system.

NETWAVE 67.5 high voltage power supply

NetWave three-phase series as a three-phase AC power quality immunity simulator is specially designed according to IEC / EN 61000-4-13,-4-14,-4-27 (pre-compatible) and -4-28 standards. As a DC power quality immunity simulator, it can also meet the requirements of IEC / EN 61000-4-17 standard for DC ripple voltage testing and IEC / EN 61000-4-29 standard for DC power supply voltage sag and short-time interruption testing.

The NetWave series is suitable for inverters (such as solar inverters, wind energy inverters) and electric vehicle testing., standards such as ISO 21498,LV 123 and similar.

Key features:

Wide Frequency Range DC - 5 kHz
Output power up to 270 kVA AC / 324 kW DC
Output voltage up to 3 x 690 V AC (p-n),± 1120 V DC
Can withstand large energy impact current
Power recovery up to nominal power (option)
Built-in arbitrary waveform generator to easily simulate complex waveforms
Standard test procedures comply with IEC / EN standards, aviation standards and MIL-STD military standard test requirements
The additional low-frequency amplifier amplifier 200Nx uses CN 200Nx to couple voltage ripples up to 500 kHz to the power line. Using the closed-loop control method, the network control software measures the voltage ripple and continuously controls its amplitude.

Signal generator NSG4070C

NSG 4070C is a multifunctional device that can perform EMC immunity testing and compliance testing according to IEC / EN 61000-4-6 and some automotive BCI standards. The modular setup of the NSG 407C0 can be used with internal or external amplifiers to suit a wide variety of applications. The powerful and easy-to-use firmware makes the NSG 4070 independent of external PCs and control software, but it can also remotely control system operations.

Key features:

Built-in pulse signal source: 4kHz ~ 1GHz
Built-in power amplifier output range: 150kHz ~ 230MHz
Test voltage Vpp: >150Vpp (considering actual insertion loss)
Pulse modulation rise and fall time:<1us
Duty cycle: 0.1%~ 100%
Modulation frequency range: 0.01Hz ~ 1MHz
Programmable through icd.control test software

High Voltage Artificial Power Network NNHV 8123-200

Key features:

Two NNHVs 8123-200 are placed inside the high-voltage shield HVSE8600, and two NNHVs 8123-200 are used to measure HV and HV-
5uH/50Ω High Voltage Artificial Network
Comply with CISPR 25, ISO 7637-4 and other standard test requirements

Pulse A Test Barron BAL 4070

Key features:

Meets ISO 7637-4, MBN 10284-3
Frequency range: 50kHz ~ 50MHz
Transmission ratio: 50Ω asymmetric to 100Ω symmetric
Input power: maximum 80W

Low Frequency Signal Source AMP 200N2

The AMP 200N2 is designed as a low-frequency signal source for generating sinusoidal signals used to simulate ripple noise and ground shift noise required by various standards in the avionics, military, and automotive industries.

The AMP 200N2 is controlled by a NetWave (used to test requirements for electric vehicles, avionics, military and marine standards. For example, LV 123 and ISO 7637-4 Pulse B). AutoWave used in automotive testing, such as the Ford FMC1278.

In addition, the AMP 200N2 generates a magnetic field through a radiating loop or a small Helmholtz coil according to various standards.

Key features:

Built-in DDS generates a sinusoidal signal up to 500kHz
Output voltage maximum 160V p-p, 50V rms
Output current maximum 18A rms
Programmable DC voltage bias

Audio transformer unit CN 200N300 for low-frequency conducted immunity testing

CN 200N300 is a single-box transformer used for low-frequency conduction immunity test. CN 200N300 is an independent coupling network, which can unify up to three audio transformers. Each transformer has a capacity of 100 A and can be configured according to various test requirements (e.g. LV 123, ISO/TS 7637-4). The CN 200N series is used to apply a test signal to the line under test through an audio transformer to perform ripple voltage test and continuous or transient conduction immunity test.

Key features:

Frequency Response 10 Hz to 500 kHz
Secondary saturation up to 300 A
Audio power 200 W per transformer
Turn ratio 2:1 step-down

For more information on ISO 7637-4 testing, visit the company's website http://www.emc-mall.com/查看。

Century Wisdom (Suzhou) Testing Technology Co., Ltd

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