Product Feb. 22, 2024

High Voltage EV-Battery Test Systems Driven by Data Loggers with 1500 V Insulation Capability

Hioki E.E. Corporation is proud to announce the release of the LR8102 (high-function model) and LR8101 (basic-function model) voltage and temperature data loggers, ideal for integration into EV battery testing systems including charge/discharge testers. The LR8102 and LR8101, optimized for integration, support the development of safe and efficient battery testing systems. These new data loggers are equipped with insulation performance up to DC 1,500 V. The high-speed communication protocols installed allow for the transfer of measurement data to the testing system within milliseconds. The measurement channels, expandable up to 3,000 channels, are ideal for simultaneously measuring all cells of high-voltage battery packs. These excellent measuring devices empower the development of EV battery testing systems.

EVs are being developed worldwide as electric mobility solutions to reduce greenhouse gas emissions. Currently, the standard voltage of EV batteries is 400 V. To achieve goals such as extending driving range, shortening charging time, and increasing output power, EV batteries with higher voltages, such as 800 V have also been developed. However, while bringing many improvements, there are also risks to consider. High voltage increases the risk of malfunctions, electric shocks, and fires.

One risk of high voltage is the possibility of insulation breakdown associated with high voltage. Insulation refers to materials or substances that prevent the flow of electric current. If a voltage higher than the allowable value is applied, the insulation can break down, leading to "short circuits" or "current leakages." These short circuits can cause malfunctions and dangerous accidents such as electric shock and fires.
Another risk is the increase in components that make up the EV battery. EV batteries are composed of units called cells, and increasing the voltage requires increasing the number of cells. Since the failure rate of the same component in electrical products is constant, an increase in components means an increased risk of failure.

Risk assessment is necessary in the development of EV batteries. Testing systems, including charge/discharge testers, are used for this purpose. Such testing systems are constantly being updated and developed along with the evolution of EV batteries. The LR8101 and LR8102 are data loggers that can be integrated and used as if they are components of these testing systems. By freeing developers from having to develop their own measurement modules within the testing system, the development period is shortened. 
Through these loggers, Hioki will contribute to enhancing the safety of electric mobility by backing the development of EV battery testing systems.

Maximum insulation withstand voltage of 1,500V

The data logger records the voltage and temperature of each cell. The data logger must function safely even against unexpected high voltage inputs. Large inputs can occur from many situations such as unintended contact of temperature sensing thermocouple with a battery cell terminal or a malfunction of just a one battery cell. If the insulation performance of the data logger is insufficient, it could cause not only failures in the testing system but also accidents such as electric shocks and fires. The LR8101 and LR8102’s insulation performance is rated at DC 1,500 V CAT II  and is compliant with the EN IEC 61010(*1) safety standard. In these ways, the 1,500 V insulation withstand voltage makes these loggers an excellent choice in constructing safe and reliable testing systems.

  • *1:EN IEC 61010: an international standard on product safety for electrical measuring instruments.

Maximum 3,000 Channels

In EV batteries, a higher voltage means a greater number of cells. To measure the voltage and temperature of all cells of a high-voltage battery, EV battery testing systems require a large number of measurement channels. The LR8102 (high-function model) can measure up to 3,000 channels by synchronizing with up to ten other units of the same logger. For measurement of less channels, the LR8101 (basic-function model) can handle up to 300 channels. With these loggers, all cells used in high-voltage EV batteries can be measured for voltage and temperature.

Extensive communication methods for system integration

Charge/discharge testing systems (one of the most common testing systems), incorporate many other devices beside data loggers such as control devices and test power supplies. For feedback control and real-time simulation, these devices must be coordinated and controlled together. To instantly share measurement data with other devices, the LR8102 and LR8101 are compatible with various communication protocols. Especially, the LR8102 supports data transfer via CAN(*2) and UDP(*3), used for controlling extensive data.

  • *2:CAN (Control Area Network): a communication protocol used for automotive development as well as on-board vehicles
  • *3:UDP (User Datagram Protocol): a data transfer protocols used in applications where speed is required, such as real-time communication




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