Insight into the high-voltage laboratory at EVOMOTIV: Expert interview with department head Daniel
In the dynamic world of electromobility, reliable high-voltage validation is crucial. EVOMOTIV, a leading provider of high-voltage testing, offers comprehensive testing for drive and energy systems. Daniel, Head of Electronics Validation at EVOMOTIV, gives us insights into the versatile possibilities and modern technologies of the high-voltage laboratory in the following interview. Find out more about the current trends, successful projects and future plans that EVOMOTIV in the field of high-voltage technology.
Dear Daniel, could you please introduce yourself briefly: Who are you and what are you doing at EVOMOTIV responsible?
“I am Daniel and have been with EVOMOTIV I am the head of the electronics validation department and am responsible for all testing in the drive and energy systems area. This also includes our internal test laboratory.”
Services and testing options in the high-voltage laboratory
What types of high-voltage tests and high-voltage validations can you perform in the high-voltage laboratory at EVOMOTIV execute?
“Our high-voltage laboratory is very broad and flexible, with the focus on electromobility. We can carry out many different types of tests. These include standard tests such as LV 124, LV 123 and ISO 16750, but also customer-specific tests, some of which we develop together with our customers. Our expertise lies in power electronics with the components inverters, DC/DC converters and onboard chargers. We are able to test almost any type of test object. In addition to the standard tests, we also offer black box and white box tests, thermal protection and endurance tests, both at the component level and at the component and system level. We are happy to work with our customers to develop individual solutions and ensure a high level of satisfaction.”
How are you equipped in the high-voltage laboratory to meet the latest requirements and standards in electromobility?
“We can display voltages of up to 1500 volts and currents of up to 1800 amps. We also have a bidirectional AC network simulation for all onboard charger applications. We are also well positioned when it comes to media temperature control and can, for example, achieve -40 °C with water-glycol cooling. This coolant mixture of water and glycol is used in automobiles, but is very viscous at low temperatures. Our system is designed to handle these conditions, which only a few systems can. We can also measure 24/7 and are absolutely suitable for continuous operation.”
Certifications, successful projects and innovations in the high-voltage laboratory
What certifications and accreditations does the high-voltage laboratory have?
“Our company is accredited according to ISO 9001 and TISAX including prototype protection. We are currently seeking accreditation according to ISO 17025, specifically for electrical tests such as LV 124, LV 123 and ISO 16750. ISO 17025 ensures that quality management in test laboratories meets the highest standards and that competent staff and appropriate work instructions are available. This accreditation makes it possible to officially label test reports, which confirms the competence and reliability of the tests carried out.”
Can you name some successful projects that were carried out in the high-voltage laboratory?
"We have Robustness tests for power electronics, including standard tests according to LV 124, LV 123 and ISO 16750. These tests were carried out for onboard chargers, DC/DC converter and Inverter We have also carried out thermal safeguards to create a database for the thermal modelling of onboard chargers. We have carried out numerous white box tests and high current tests for cell connectors and fuses. We are currently preparing abuse tests for battery cells, a project that will start soon.”
Which special innovations or research results from the high-voltage laboratory are particularly noteworthy?
“We have developed our own control software for our test benches. We are particularly proud of the fact that we build our test benches ourselves. This enables us to design the test benches exactly according to our needs and to use them flexibly.”
Quality assurance and cooperation in the high-voltage laboratory
How do you ensure that customer requirements for high-voltage testing are always met?
“An essential part of project implementation is the close cooperation between us and the customer. We work not only as a service provider, but as a partner who actively thinks along. If something in a test specification seems implausible to us, we contact the customer to make sure that everything is correct.
Our test benches are flexible and can be modified according to customer requirements. We also have the ability to integrate new equipment and configure test benches for different purposes. This flexibility and dynamism are great advantages when it comes to responding to customer requests.”
Daniel, Head of Electronics Validation at EVOMOTIV
How do you work with other departments in the high-voltage laboratory to achieve optimal results in high-voltage safety tests?
“Within the business area, we work closely together and use the know-how of our employees. If someone has built up specific knowledge at a customer, we incorporate this experience into our work.”
Positioning and future plans of the high-voltage laboratory
How does the high-voltage laboratory position itself in EVOMOTIV in the current market environment of electromobility and high-voltage technology?
“We want to be a broadly positioned testing partner that not only offers standard tests, but also responds flexibly to customer requests. Every request is examined intensively in order to be able to provide the best possible assistance. We live our company values every day and are open to requests from various areas that match our competencies.”
Does this differentiate you from other competitors or HV labs?
“The feedback from our customers clearly shows that they particularly value our flexibility and our ability to think along with them. Many customers see a great advantage in the fact that we deal intensively with their products and the specific test specifications.”
What current market trends do you see in the area of HV technology?
“We are currently seeing exciting developments in product integration that combine various technologies. For example, one manufacturer integrates separate units for inverters, onboard chargers and DC/DC converters in its vehicles, while another manufacturer combines the onboard charger and DC/DC converter in one device. A third manufacturer finally combines all three components in a single unit. These different approaches require a high degree of flexibility in our test benches in order to effectively meet the diverse requirements. When testing an inverter together with a DC/DC converter, both components must work optimally in their respective operating ranges. This requires a special test bench configuration, possibly with additional power supplies or a second cooling system.
This integration is also visible at the drive level. There are drives that combine inverter, electric motor and transmission in one device. Reproducing these complex systems on a test bench that takes all components into account at the same time is a challenge. We at EVOMOTIV However, we strive to ensure this flexibility in order to provide our customers with the best possible support.
Another positive trend is the rapid development of technology. While electromobility has so far mostly been based on 400 volts, the first 800-volt systems are now appearing. This exciting development offers new opportunities and challenges. It is possible that we will have to plan for even higher voltage levels in the future. This dynamic drives us and ensures that our equipment is always future-proof and state-of-the-art."
What future plans do you have for the further development of your services?
"Our short-term goal is to be able to offer accredited tests in order to further underline the high quality of our services. We are also intensively examining the possibility of entering battery testing, with a particular focus on abuse tests, as there is a significant need for this. Another exciting project is the development of a test bench for electric machines, for which planning is already well advanced. These projects demonstrate our ongoing efforts to develop innovative and future-oriented services."
Dear Daniel, thank you very much for the detailed interview and the exciting insights!
Interested in our services? On our Website You can find more information here or contact us directly to find out more about our tailor-made solutions in the field of high-voltage testing and electromobility.
The environmental policy of EVOMOTIV is aimed at controlling, regulating and minimising the impact of business and human activities on the environment. This is achieved through a variety of measures and initiatives:
1. Resource efficiency and conservation: EVOMOTIV focuses on economical use of energy and water. Standby modes are avoided and energy-saving IT devices are used.
2. Raising awareness among employees: Through lock screens, e-learning and tips on In-house events raise employees’ awareness of environmental issues.
3. Promoting biodiversity: EVOMOTIV expands green spaces and builds refuges for insects, such as flower meadows, green roofs and bee hotels.
4. Sustainable food: EVOMOTIV focuses on local, seasonal and fairly traded food and relies on reusable tableware.
5. Paperless office: EVOMOTIV aims to work completely paperless.
6. Use of renewably produced fuels: Until the fleet is fully electrified, the focus will be on fuels obtained from renewable energy sources.
7. Electrification of the fleet: EVOMOTIV plans to electrify its fleet to reduce CO2 emissions.
8. Ecologically produced merchandise: EVOMOTIV buys environmentally friendly gifts for employees and customers.
9. Reduction of data waste: EVOMOTIV is committed to reducing data waste in order to minimize the environmental impact of digital waste.
EVOMOTIV is committed to continuously improving environmental performance through business practices and strategies and to actively contributing to environmental protection, with the clear aim of promoting sustainable development.
social commitment
Our central sustainability motive is to make a positive contribution to people and the environment. Under the principle << Inspire people, develop values >> we are involved in a variety of ways directly in the region of our locations in order to promote a variety of charitable projects.
sponsoring
A selection of the organizations that are particularly close to our hearts:
Donation
Our social commitment is reflected in our support of various non-profit organizations. Our colleagues are actively involved, for example through actions such as “Cycling for a good cause“. Through such initiatives we collect donations, which we donate to, for example Children's Hospice Munich as well as the support association Helping Hands . We also take part in campaigns such as: Christmas in a shoe boxto make a sustainable contribution to social issues.
Our climate strategy
Our main goal is to proactively avoid greenhouse gas emissions. We consistently rely on environmentally friendly technologies, processes and behavioral changes in order to minimize emissions from the outset.
At EVOMOTIV, we understand reduction as the decrease of existing greenhouse gas emissions. To achieve this, we rely on more energy-efficient technologies, optimize business processes, and implement targeted energy-saving measures.
Our self-generation strategy aims to reduce the need for fossil fuels and achieve CO₂e-neutral energy production and supply. We achieve this using renewable energy sources such as photovoltaics or heat pumps.
If self-generation is not feasible, we plan to obtain the remaining energy requirements from renewable sources. In this way, we ensure a sustainable energy supply.
As a final step, we only resort to compensatory measures if all previous steps are not sufficient. We compensate for unavoidable or irreducible greenhouse gas emissions by reducing or sequestering emissions elsewhere.
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