Conducted Immunity Ing On Automotive Electronics CI230 20098022ppt2

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Conducted Immunity Tests for
Automotive Electronics
Automotive EMC Seminar - IEEE HK

Jeffrey Tsang
Jeffrey.tsang@teseq.com

Teseq Group

27th November 2006

2

Teseq Group
Luterbach, Switzerland
Our competence center for conducted
equipment:
ESD
Burst
Surge
Power Quality
Automotive
SCS Accredited Calibration Centre
Headquarters
3

Teseq Group
Berlin, Germany

Our competence center for
RF Equipment
GTEM Cell, Reverberation Chamber
EMC System
DKD accredited Calibration Centre

4

Teseq Group
Wokingham, UK

Our competence center for
Compliance 3 Software
EMC System Project
Power Amplifier
UKAS accredited Calibration Centre

5

Turnkey Projects

3m Anechoic Chamber
Radiated Emission System
Radiated Immunity System
ESD
Conducted Emission
6

Conducted Immunity

Turnkey Projects

CISPR25 Emission System x2
600V/m Radiated Immunity
System

ESD
BCI System
新加坡PSB

香港天祥

Transient Immunity System

Magnetic Field Immunity
Stripline, TEM Cell
Optical EUT Monitoring
7

Turnkey Projects

200V/m Radiated
Immunity System
Automatic EUT monitoring
System

Alpine China
大连阿尔派
8

上海天祥

Turnkey Projects

ESD
BCI System up 400mA
Transient Immunity
Magnetic Immunity
1kW Power Amplifier – 200V/m
Radiated Immunity System

9

中国电器科学研究院

Conducted Immunity Testing on Automotive Electronics:

From ISO 7637 to Introduction of Manufacturer standards

10

What is EMC?
Special Considerations for Motor Vehicles

In ISO 7637 and variants, we are considering transients and voltage drops that
are coupled over battery lines and signal lines

Immunity Testing simulates ‘Conducted EMC’ that occurs during normal or
error conditions in a motor vehicle.
Emissions testing ensures that the noise created by a device is less than
specified levels.
Evaluates the performance of components during simulated real-world EMC
events

These failure conditions are documented and tests defined by International
organizations (ISO, SAE) and manufacturers (Ford, VW)

11

Why EMC is important?
Causes:
Alternators, Converters, Switching Processes
Electric Motors, Fuel Pump, Fan Motors

Before production and sampling during
production

Lights, Radio

During redesigns or modifications

Every kind of electronic device

During initial design phases

Coupled on Power Lines and Wiring Harnesses
Engine Start

12

When devices shall be tested:

Automotive EMC
Automotive EMC

Immunity

ESD

RF
Magnetic

Conducted
Transient

Emission

Voltage
Fluctuation
Many test cases

13

Conducted Conducted
Continuous
Transient

RF

Distinct Characteristics in
Automotive Conducted EMC
DC 12V, 24V, 42V
Lots of different Transients
Positive and Negative Transients
Emission and Immunity Tests
Lots of Voltage Fluctuation
Extremely detailed in test setup:
Harness height and length
Separation
Test Fixture
Load Simulator
Very long test time
14

Automotive Conducted EMC Setup
EUT is set to be in operation mode(s)
Test Fixture
Load simulator

15

EUT example:
Climate Control
Console

EMC Standards in Automotive Industry
Manufacturers (OEM)

International Bodies
ISO
IEC / CISPR

No so difficult

Regional Requirement
2004/104/EC (e-mark)
SAE (SAE J1113-11, SAE J1113-12)
JASO
GB/T
16

Much more
complicated

BMW
Daimler Chrysler
Fiat
Ford
General Motors
Honda
Hyundai
Mazda
Peugeot
Nissan
Renault
Toyota
Volkswagen
...More!

ISO Standards on Automotive Electronics
ISO 7637-2: Conducted Transient on power line
7 tests
ISO 7637-3: Conducted Transient no non power line
4 tests
ISO 16750-2: Environmental conditions and testing
for electrical and electronic
6 out 10 tests are voltage fluctuation
ISO 10605: ESD

Lots of the test cases
are introduced and
modified in OEM
Standards
Usually in a more
harsh way

All these tests simulate typical electrical environment in a full vehicle
17

Conducted Transient Immunity
&
Voltage Fluctuation

18

OEM standards refer to ISO but different
Different automotive standards require different transient pulses. The
requirements are different in:







Amplitude
Impulse
Frequency
Pulse energy
Test method, test setup

What are the causes of differences?

19






Wiring harness
Components

Generators
etc.

Conducted Immunity Tests Summary
ISO7637-2
Pulse 1
Pulse 2a
Pulse 3a
Pulse 3b
Pulse 4
Pulse 5a
Pulse 5b

20

Ford
ES-XW7T-1A278-AC
CI 210
CI 220
Pulse A1
Pulse A2
Pulse B1
Pulse B2
Pulse C
Pulse D
Pulse E
Pulse F
Pulse G
CI 230
CI 250
CI 260
Waveform A
Waveform B
Waveform C
Waveform D
Waveform E
CI 270

Nissan
28401NDS02
EQ/TE 01
EQ/TE 02
EQ/TE 03
EQ/TE 04
EQ/TE 05
EQ/IC 01
pulse 1
pulse 2
EQ/IC 02
pulse 3a
pulse 3b
EQ/IC 03
EQ/IC 04
EQ/IC 05
EQ/IC 06

Volkswagen
TL 82066
Pulse 1
Pulse 2
Pulse 3
Pulse 4
Pulse 4b
Pulse 5b
Pulse 6

Test Purpose of ISO 7637-2
Test Pulse 1
This test is a simulation of transients due to supply
disconnection from inductive loads; it applies to a
DUT if as used in the vehicle, it remains connected
directly in parallel with an inductive load.(1)

DUT

Inductive Load
Battery
21

Test Purpose of ISO 7637-2
Test Pulse 1 Variant
Ford
ES-XW7T-1A278-AC
CI220 pulse E (12V only)

ISO 7637-2

Nissan
28401NDS02
EQ/IC 01 Pulse1 (12V only)
Volkswagen
TL 82066

24V

22

Test Purpose of ISO 7637-2
Test Pulse 2a
Pulse 2a simulates transients due to
sudden interruption of currents in a
device connected in parallel with the
DUT due to the inductances of the
wiring harness.

Switch off Lamp

DUT

Load
23

Battery

Test Purpose of ISO 7637-2
Test Pulse 2a Variant
Ford
ES-XW7T-1A278-AC
CI220 pulse F (12V only)

ISO 7637-2

Nissan
28401NDS02
EQ/IC 01 Pulse 2a (12V only)
Volkswagen
TL 82066

24

24V

Test Purpose of ISO 7637-2
Test Pulse 2b
Pulse 2b simulates transients from dc motors acting as generators after the ignition is
switched off
It is more like a voltage fluctuation test. Most car manufacturers had withdrawn this
because it is covered by other voltage fluctuation tests
Ignition Switch

DUT

DC Motor
Battery
25

Test Purpose of ISO 7637-2
Test Pulse 3a/3b
Pulse 3 occurs as the result of
switching processes. The
characteristics of this pulse are
influenced by distributed
capacitance and inductance of the
wiring harness.

3a
DUT
3b
26

Battery

Test Purpose of ISO 7637-2
Test Pulse 3a/3b Variant
Most manufacturers bring these tests into their own EMC standards except Ford
General Motor
GMW3097
Nissan
28401NDS02
EQ/IC 02 Pulse 3a/3b
Pulse width
td = 100ns
Volkswagen
TL 82066 Pulse 3a/3b

27

Test Purpose of ISO 7637-2
Test Pulse 4
Pulse 4 is the voltage reduction caused by
energizing the starter motor circuits of the
internal combustion engines
DUT

Battery
28

M

Test Purpose of ISO 7637-2
Test Pulse 4
All manufacturers requires Starting Profile test but in more complicated way

Nissan
28401NDS02 EQ/IC 05
Resistant to starting profile
29

Volkswagen
TL 82066 Pulse 4/4b

Test Purpose of ISO 7637-2
Test Pulse 4 Variant
Very Complicated Starting Profile tests

This test is to be
done at -40ºC or
below

30

Ford
ES-XW7T-1A278-AC CI230
Power Cycling

Nissan
28400NDS02
Momentary power source voltage
drop resistant

Test Purpose of ISO 7637-2
Test Pulse 5a/5b

5a

Pulse 5 is a simulation of a load dump transient
occurring in the event of a discharged battery
being disconnected while the alternator is
generating charging current with other loads
remaining on the alternator circuit at this
moment

Motor
5b

Disconnect
Battery Lead

DUT

Alternator
Generating Charging Current

Battery
31

Test Purpose of ISO 7637-2
Test Pulse 5a/5b variant
All manufacturers requires Load Dump test but almost all of them are specified in
different ways
This pulse generate high energy and often destructive

Ford
ES-XW7T-1A278-AC
CI220 pulse G
Pulse 5a

Pulse 5b
32

Nissan
28401NDS02
EQ/IC 03 Pulse 5a/5b

Volkswagen
TL 82066 Pulse 5b
Only applicable to 42V system
Ri = 3Ω

Test Purpose of ISO 7637-2
Test Pulse 5a/5b

85V

Pulse 5a

400ms

13.5V
0V

Pulse 3a
-100V

Pulse 1
-150V

33

Manufacturer EMC Standards Tests
Ford ES-XW7T-1A278-AC CI220

Pulse A1

Pulse A2

Pulse C

These pulses are caused by actual mechanical relay with defined circuitry
34

Manufacturer EMC Tests
Nissan
28401NDS02
EQ/IC 04 : Resistance to power supply micro-interruptions

35

Manufacturer EMC Tests
Siemens VDO
Fuel Pump Transient test for IPC

36

Pulse Generation System
Typical Setup

Photograph Courtesy of CVC

37

Teseq Pulse Generation System
Teseq Conducted Immunity System
Automotive Electronics

Transients
NSG5500

NSG5600

PA 5840

Voltage
Fluctuation
38

ISO
SAE
JASO
BMW
Daimler Chrysler
Fiat
Ford
General Motors
Honda
Hyundai
Mazda
Peugeot
Nissan
Renault
Toyota
Volkswagen
Etc..

Conducted Transient Emissions

39

ISO 7637-2 Emission

Automotive EMI
CISPR12, 25 –> Continuous Interference
ISO 7637-2 -> Transient due to switching process
ISO 7637-2
Must do test
Test procedure is straight forward
Lots of details in test setup
Lots of mal-practice in the market

40

ISO7637-2 Emissions Test Layout

AN

“Slow Pulse” Setup

41

DUT

AN

“Fast Pulse” Setup

Cable lengths, 50 -0/+10 mm above GND plane, disturbance voltage
shall be measured as close to the DUT terminals as possible

DUT

ISO 7637-2 Emissions Test Layout

Application
Wiring
Harness

For applications where the DUT is
far from the switch, the setup
should have the AN between the
switch (simulating the wiring
harness) and the DUT.
“Slow Pulse Setup”
Millisecond range or slower
Oscilloscope

Switch

Test Setup

DUT
Battery
Source

42

Artificial Network
Simulates Wiring Harness
Impedance

ISO 7637-2 Emissions Test Layout

Application
Wiring Harness

For applications where the DUT is
near the switch, the setup should
have the AN before the switch
“Fast Pulse Setup”
nanosecond-to-microsecond range

Oscilloscope
Artificial Network
Simulates Wiring Harness
Impedance

Test Setup

43

Battery
Source

Switch

DUT

Emissions Relay or Electronic Switch?

When to use a relay and when the electronic switch:
Relay
Voltages over 400V
Usually must be approved by OEM
Poor Repeatability, Slow/Chattering
Must be replaced
Should be production relay from the
vehicle containing the DUT
Electronic Switch
Less than 400V
Fast and Repeatable
Voltage Drop Must be Accounted
For ∆U ≤ 1V at 25 A
44

Potter & Brumfield

Bosch

Differences: AN(LISN) defined in
ISO7637-2 & CISPR25
ISO 7637 and CISPR 25 Artificial Network are NOT the same
CISPR 25

Differences Between ISO 7637 and CISPR25 Artificial Networks
45

How to measure?

Test procedure is quiet straight forward but has to be
done manually
Search for the worst cases (highest amplitude) by:
Changing the switch on/off time
Changing the switching repetition

46

Typical Measurement Result
Very Heavily Inductive

~450 V

47

Mixed R/L Load

~20 V

Much more severe pulses from DUTs with high inductance

ISO7637-2 Emissions Limits

Ford
ES-XW7T-1A278-AC
CE410 Limits <+100V, >-150V
Only use Fast Pulse setup

48

Volkswagen TL 82066
Maximum permissible transient emission
Only use Fast Pulse setup

49

Nissan 28401NDS02 EQ/MC 01
Measurement of conducted transient emission

50

Nissan 28401NDS02 EQ/MC 01
Measurement of conducted transient emission
Complicated Measurement Setup

51

Teseq Transient Emission System
Photograph Courtesy of HKPC

Detectable switch

Artificial
Network
Control unit

AES 5500
52

www.teseq.com
Jeffrey Tsang
Jeffrey.tsang@teseq.com
53

Thank you!

Your Teseq partner:
Hong Kong
Denetron International
Limited
+852 2 707 9132
dhk@denetron.com.hk



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Page Count                      : 53
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Title                           : Conducted Immunity Testing on Automotive Electronics
Author                          : Jeffrey Tsang
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Modify Date                     : 2009:08:23 15:13:49
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