Evaluation of Cable Harness of an Electric Vehicle Powertrain through Simulation

The Electric Vehicles (EV) or Hybrid Electric Vehicle (HEV) has a bunch of electrical/electronic components and its operation give rise to complicated EMI/EMC issues. The Power Electronics Module (PEM), comprising of DC-DC convertor/invertor and Battery Management Unit (BMU), is driving the motor to propel the vehicle. “Battery Pack Module” powers these units through cables. The fast switching of these circuit elements present in the system leads to noise propagation through the cables. These noise signals give rise to various Electromagnetic (EM) related issues in the cable harness of vehicle. It is essential that these cables should not interfere with other electronic components and also does not get effected by external EM disturbances. The critical EM aspects such as Cable Coupling, Immunity of cable in EM environment (Radiated Immunity) as per AIS-004, Emission from the power cables (Radiated Emission) as per AIS-004, Shielding Effectiveness for cable harness of the EV powertrain is analysed through simulations. A robust methodology is developed to carry out the EM Simulation by overcoming the constraints because of the available inputs to carryout simulation. The simulation methodology developed shortens the product development cycle, which is of great interest to EV and HEV manufacturers. It also helps to get a clear picture to understand the EMI/EMC compliance of vehicle/ system in design stage itself.