A production line with large rectangular battery cells that are assembled in a modern factory.

High-voltage test benches with Bender technology

In the modern automotive industry, high-voltage test benches are essential to ensure the safety and efficiency of components such as batteries, inverters and electric drives. These test benches work with high voltages and currents and allow several test specimens to be monitored simultaneously. In the event of insulation faults, they ensure a safe shutdown.

The aim is to develop innovative and efficient system solutions for the drivetrain. These technologies are intended to increase the safety and reliability of electrical vehicle components and thus contribute to sustainable mobility.

The central challenge

One of the biggest challenges is to find a reliable insulation monitoring solution that reacts immediately if an insulation limit value is exceeded. This is crucial to avoid dangers from residual currents. A trusted partner with proven solutions is essential here.

Advantages of the ISOMETER® iso685

  • Precise insulation monitoring: Continuous measurement of the resistance value to earth.
  • Safety adaptability: Flexible parameter setting for different test bench environments.
  • Intuitive operator control: A user-friendly interface for simple configuration and data analysis.
  • Long-term documentation: Seamless logging of measured values for comprehensive safety verification.

Project example: South German automobile manufacturer

In a specific project for a southern German car manufacturer, Schaeffler has developed high-voltage test benches that operate with up to 1,000 V voltage and 2,000 A current. These test benches can be used to test components such as batteries and electric drives safely and efficiently. They are designed to monitor several test specimens simultaneously and initiate a safe shutdown in the event of insulation faults.

The choice of partner

When it came to selecting a suitable IMD (Insulation Monitoring Device), the ISOMETER® iso685-D was chosen. Positive experiences and the broad acceptance of these products were decisive factors in this decision.

Despite a tight time frame of just six months for the completion of the first series and global supply chain bottlenecks, the project was successfully completed. A total of 70 ISOMETER® iso685-D devices were integrated into the test benches. Further series productions are already in the works.

Smooth implementation

The integration of the devices went smoothly. Thanks to the great commitment of the team, a solution was found that meets the requirements.

"The collaboration was outstanding. The team provided us with live support to make the devices available on time, which was anything but a matter of course given the bottlenecks at the time."

Results and outlook

Thanks to the reliable monitoring technology, it has been possible to develop high-voltage test benches that meet the highest safety requirements. This concept will also be used in future projects in order to continue delivering innovative solutions for the automotive industry.

Products

Insulation monitoring

ISOMETER® iso685…
ISOMETER® iso685…

Insulation monitoring device for inverter applications and large industrial plants

Insulation monitoring

ISOMETER® iso685…
ISOMETER® iso685…

Insulation monitoring device for inverter applications and large industrial plants

Details

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