arrow_back_ios

Main Menu

See All Acoustic End-of-Line Test Systems See All DAQ and instruments See All Electroacoustics See All Software See All Transducers See All Vibration Testing Equipment See All Academy See All Resource Center See All Applications See All Industries See All Insights See All Services See All Support See All Our Business See All Our History See All Our Sustainability Commitment See All Global Presence
arrow_back_ios

Main Menu

See All Actuators See All Combustion Engines See All Durability See All eDrive See All Production Testing Sensors See All Transmission & Gearboxes See All Turbo Charger See All DAQ Systems See All High Precision and Calibration Systems See All Industrial electronics See All Power Analyser See All S&V Hand-held devices See All S&V Signal conditioner See All Test Solutions See All DAQ Software See All Drivers & API See All nCode - Durability and Fatigue Analysis See All ReliaSoft - Reliability Analysis and Management See All Test Data Management See All Utility See All Vibration Control See All Acoustic See All Current / voltage See All Displacement See All Load Cells See All Pressure See All Strain Gauges See All Torque See All Vibration See All LDS Shaker Systems See All Power Amplifiers See All Vibration Controllers See All Accessories for Vibration Testing Equipment See All Training Courses See All Whitepapers See All Acoustics See All Asset & Process Monitoring See All Custom Sensors See All Data Acquisition & Analysis See All Durability & Fatigue See All Electric Power Testing See All NVH See All Reliability See All Smart Sensors See All Vibration See All Weighing See All Automotive & Ground Transportation See All Calibration See All Installation, Maintenance & Repair See All Support Brüel & Kjær See All Release Notes See All Compliance See All Our People
arrow_back_ios

Main Menu

See All CANHEAD See All GenHS See All LAN-XI See All MGCplus See All Optical Interrogators See All QuantumX See All SomatXR See All Accessories See All Accessories See All BK Connect / Pulse See All API See All Microphone Sets See All Microphone Cartridges See All Acoustic Calibrators See All Special Microphones See All Microphone Pre-amplifiers See All Sound Sources See All Accessories for acoustic transducers See All Experimental testing See All Transducer Manufacturing (OEM) See All Accessories See All Non-rotating (calibration) See All Rotating See All CCLD (IEPE) accelerometers See All Charge Accelerometers See All Impulse hammers / impedance heads See All Cables See All Accessories See All Electroacoustics See All Noise Source Identification See All Environmental Noise See All Sound Power and Sound Pressure See All Noise Certification See All Industrial Process Control See All Structural Health Monitoring See All Electrical Devices Testing See All Electrical Systems Testing See All Grid Testing See All High-Voltage Testing See All Vibration Testing with Electrodynamic Shakers See All Structural Dynamics See All Machine Analysis and Diagnostics See All Calibration Services for Transducers See All Calibration Services for Handheld Instruments See All Calibration Services for Instruments & DAQ See All On-Site Calibration See All Resources See All Software License Management

Analysis of Multiple Load Cases in a Single Test Bench Environment at HUBER + SUHNER

huber+suhner, Switzerland

Introduction

Connected to the Future of Electromobility
Whether by train or car, the mobility of the future will be electric in terms of energy transition. In case of railway networks already powered by electricity, trains have prevailed. On the road, hybrid and electric vehicles are becoming increasingly important. Also, in aviation, electrically powered aircrafts are on the rise. Electric means of transport should be energy-efficient, safe, and comfortable. Thanks to high-quality connection technology from HUBER + SUHNER (H + S), this becomes possible. The company HUBER + SUHNER develops and produces cables, connectors, and cable systems for data and energy transmission, offering high-frequency and low-frequency technologies as well as fiber optic products from a single source.

chevron_left
chevron_right

The HUBER + SUHNER RADOX® cables and their use in HPC high power charging system

In charging stations, cables and cable connections are exposed to strong vibrations, extreme temperatures, and aggressive fluids throughout their lifetime. There are rather high demands of the quality, longevity and temperature resistance of the cables and systems used. RADOX® multicore cables have high resistance and resistance to heat. They have been specifically developed for the construction of compact and lightweight high-performance equipment. To ensure continued use in electrical charging stations, the cables are tensioned for testing in a torture bench and subjected to millions of load cycles.

Test bench setup

HUBER + SUHNER, the world leader in interconnect technology, uses state-of-the-art automated test rigs with robots to test its cables, able to appraise a wide variety of load cases. The complete measuring chain from HBK is used for acquiring the necessary measurement data with large data volumes and high precision requirements.

Modern bench-top robots characterize the cables to the predefined loads. For this purpose, different load profiles are run through at different ambient temperatures in a climatic chamber. The cables are also visually checked during the test to determine possible changes to the surface of the insulation jacket. In order to obtain stable and traceable measurement data, HBK's complete measurement chain is used for the long-term tests – from the precise sensors to the data acquisition to the intuitive software, which analyzes large amounts of data in just a few clicks. A reliable measuring chain without system breaks is thus guaranteed. According to Mr. T.-M. Schmid, a technician at H + S, this aspect opens up new dimensions for the use of modern robots and their degree of freedom in the test bench environment. Thus, for example, several load cases can be covered; whether it be a bending test, torsion test or complete 1: 1 simulated movements, all possible load cases can be realized with a working machine.

The trick is to find and record the relevant measurement points and quantities to detect material changes in the cables. For this purpose, sensors for force, torque, rotation angle, and temperature are used. The data acquisition system QuantumX and the catman® software from HBK are used for data acquisition and analysis.

Fatigue analysis with catman®: Classification method (peak-valley analysis)

The modern testing concept of cables enables exact and reliable lifetime analyses for cables in charging stations—a special, yet significant, contribution to the future of electromobility.

For long-term tests, the maximum forces or torques that occur must be precisely determined repeatedly. For this purpose, the analogue pickup signals are digitized and recorded with high precision and high dynamics. As the measurement takes several months, significant amounts of raw data have to be analyzed. Thanks to an intelligent data reduction method in the catman® data acquisition software, only the relevant minima and maxima of the sensor signals are stored, which enables a considerable data reduction. At the same time, a cycle counter runs, evaluating the minima and maxima. The test can be stopped after a given number of cycles (through intelligent triggers). The statistical trend of the minima and maxima signal values, in turn, is also analyzed online and included in the event or alarm monitoring. In the simplest case, alarms can change the signal color (blue-> red) or generate actions such as an entry in the logbook, push message to the mobile phone, camera activation, storage of all raw data, and much more. During the measurement, the data is periodically secured in a defined time secured distances. The counter is not affected. To stop the measurement, a defined maximum change of the minima or maxima values is used as a stop trigger. The service life of the cables is determined by the number of real load cycles achieved. No programming skills are required to realize this demanding measurement and test task. Electric mobility requires intelligent solutions. H + S is ready to make a significant contribution here. HBK provides support for this process with quality tools for metrological evaluation in the test. In addition, HBK offers further opportunities for electrical tests as well as for the performance and efficiency analysis of batteries.

HUBER + SUHNER - Excellence in Connectivity Solutions

Being headquartered in Herisau, Switzerland, HUBER+SUHNER help our customers making strong and reliable connections happen by transporting data and power in networks. And serve our three main markets of industry, communication, and transportation with applications from three technologies: radio frequency, fiber optics and low frequency.

More about HUBER+SUHNER

Technology Used

Related Case Studies