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Efficiently testing power electronics of e-vehicles

New system from Bosch Engineering for high-voltage components

  • High-voltage lab rig (HVLR) integrates high-voltage power supply and electronic safety functions in a modular system
  • Moving tests from the test bench to the high-voltage lab reduces development time and costs
  • High-voltage safety box (HVSB) ensures safe working conditions on high-voltage circuits
Cornelia Dürr

Cornelia Dürr

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Cornelia Dürr

Cornelia Dürr
Spokesperson for Bosch Engineering GmbH, motorsports

Holzkirchen – The number of electric vehicles on offer is steadily increasing worldwide. As a consequence of this growing number of new models and platforms, engineering work involved for the vehicles’ high-voltage system components is on the increase too. This is where Bosch Engineering comes in: with its new high-voltage lab rig (HVLR), the company now offers a fast, efficient and, above all, safe solution for testing the electric vehicle power electronics in the development lab. The system integrates a high-voltage power supply and electronic safety functions for the circuit of the component under test in a portable compact control cabinet. “Many of the tests on the power electronics of electric vehicles can therefore be shifted from the test bench to the high-voltage laboratory. This frees up valuable bench capacity for other testing and validation tasks, thereby reducing development time and costs,” says Andreas Nachreiner, Head of Product Management Business Field eMobility at Bosch Engineering.

Thanks to its modular design, the test system can be flexibly adapted to individual customer requirements. For example, different voltage levels of up to 1200 volts as well as different communication interfaces and an optionally integrable dummy load can be selected. Subsequent upgrading, for example to higher output voltages of up to 1500 volts, is possible as well. The system is conveniently operated via a touch-screen display. The monitor also provides a clear-cut overview of all operating parameters such as status messages, information on system settings, and any error warnings.

High level of safety against life-threatening voltage

A key focus in the design of the high-voltage lab rig was safety in everyday test operations. “In the laboratory, a large number of tests have to be carried out directly on the live components of the power electronics. Any mistakes here are life-threatening. Our protection concept covers potential causes of accidents and reduces the risks when working on the high-voltage circuit,” explains Heinz-Georg Schmitz, Director Engineering Mechatronic Solutions at Bosch Engineering. Another resulting advantage is the protection of the test object from damage during testing. This is particularly advantageous for prototype components that are only available in small quantities and where defects would lead to delays in the development process.

The safety functions are implemented by a separate unit, the high-voltage safety box (HVSB). This was developed in accordance with DIN EN ISO 13849 and offers, among other things, isolation monitoring, an interlock circuit, integration into a laboratory emergency shut-off concept and a PLC interface with which the HVLR can be seamlessly integrated into the test automation of the high-voltage laboratory and operated remotely. The high-voltage safety box is included with the high-voltage lab rig, but is also available as a separate module, for example to retrofit the safety functions and the PLC interface to existing high-voltage power supplies.

Mobility is the largest Bosch Group business sector. In 2023, its sales came to 56.2 billion euros, or just under 60 percent of total Group sales. This makes the Bosch Group one of the leading mobility suppliers. Bosch Mobility pursues a vision of mobility that is safe, sustainable, and exciting. For its customers, the outcome is integrated mobility solutions. The business sector’s main areas of activity are electrification, software and services, semiconductors and sensors, vehicle computers, advanced driver assistance systems, systems for vehicle dynamics control, repair-shop concepts, as well as technology and services for the automotive aftermarket. Bosch is synonymous with important automotive innovations, such as electronic engine management, the ESP anti-skid system, and common-rail diesel technology.

About Bosch Engineering GmbH
Bosch Engineering GmbH is a wholly owned subsidiary of Robert Bosch GmbH and is head-quartered in Abstatt, Germany. As a systems development partner to the automotive industry since 1999, the company with its more than 3,000 associates offers development services for powertrains, safety and convenience systems, and electrical and electronic systems – from the original concept to series production. Specialized in electronics and software, it draws on Bosch’s proven large-scale series production technology to develop tailored solutions for a wide variety of applications in passenger cars, commercial vehicles, off-highway and recreational vehicles, and in rail applications, ships, and industry. Bosch Engineering GmbH also coordinates all the Bosch Group’s motorsports activities.

Additional information can be accessed at www.bosch-engineering.com.

The Bosch Group is a leading global supplier of technology and services. It employs roughly 429,000 associates worldwide (as of December 31, 2023). The company generated sales of 91.6 billion euros in 2023. Its operations are divided into four business sectors: Mobility, Industrial Technology, Consumer Goods, and Energy and Building Technology. With its business activities, the company aims to use technology to help shape universal trends such as automation, electrification, digitalization, connectivity, and an orientation to sustainability. In this context, Bosch’s broad diversification across regions and industries strengthens its innovativeness and robustness. Bosch uses its proven expertise in sensor technology, software, and services to offer customers cross-domain solutions from a single source. It also applies its expertise in connectivity and artificial intelligence in order to develop and manufacture user-friendly, sustainable products. With technology that is “Invented for life,” Bosch wants to help improve quality of life and conserve natural resources. The Bosch Group comprises Robert Bosch GmbH and its roughly 470 subsidiary and regional companies in over 60 countries. Including sales and service partners, Bosch’s global manufacturing, engineering, and sales network covers nearly every country in the world. Bosch’s innovative strength is key to the company’s further development. At 136 locations across the globe, Bosch employs some 90,000 associates in research and development, of which nearly 48,000 are software engineers.

Additional information is available online at www.bosch.com, www.iot.bosch.com, www.bosch-press.com.

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