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

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.

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

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. HBM provides support for this process with quality tools for metrological evaluation in the test. In addition, HBM offers further opportunities for electrical tests as well as for the performance and efficiency analysis of batteries.