The accelerating shift to electric mobility is marking a profound change in the landscape of the modern transportation industry. The need for precision and innovation in key components is more apparent than ever as electric vehicles (EVs) become an integral part of our mobility world. At the forefront of this revolution are advances in current sensing technologies, particularly those related to shunts: the silent heroes of electric mobility.
Michael Richter, responsible for shunts at Wieland, and Michael Wolf, in charge of Qulectra, share how the combined engineering experience of the Wieland Group and Munich Electrification is aiming to shape the future of electric mobility.
UNDERSTANDING SHUNTS
Shunts are essentially precision resistors. They play a central role in the complex systems of EVs. They enable highly accurate state of charge (SOC) calculations within EV batteries as the heartbeat of current measurement. This function is critical to the optimisation of battery performance, efficient energy management and ultimately the longevity and reliability of EVs.
At a time when sustainability and environmental awareness are taking centre stage, electric mobility is becoming a driving force for change. A collective commitment in reducing carbon emissions and embracing cleaner, more sustainable transportation solutions is evident in the growing adoption of EVs. To meet the evolving demands of the electrified future, this paradigm shift underscores the need for cutting-edge technologies.
SHUNTS WITH PRECISION AND EXPERTISE
Against this backdrop, the cooperation between the Wieland Group and Munich Electrification, embodied in the joint venture Qulectra, takes centre stage. Wieland’s 200 years of expertise in copper materials blends seamlessly with Munich Electrification’s expertise in chips and software. Together they are embarking on a journey to redefine current sensor technologies, especially in the context of EVs.
The Wieland Group, a leading copper manufacturer, is a major contributor to the development of current sensing technologies. The company offers a range of shunts in various standard dimensions as well as customised configurations. With in-house development, prototyping and production capabilities, Wieland aims to ensure the highest standards in shunt manufacturing.
Wieland’s shunts are manufactured in standard sizes and can also be customised to meet specific customer requirements. Leveraging the company’s expertise in copper, these shunts have resistivity values ranging from 25 to 100µΩ, providing a broad spectrum to meet a variety of applications. As a copper manufacturer, Wieland’s shunts benefit from the company’s core competence in copper-related technologies.
The result of this collaboration is a new generation of advanced shunts that go beyond conventional limits. These shunts not only embody metallurgical excellence, thanks to Wieland’s copper expertise, but also integrate intelligent functionalities, thanks to Munich Electrification’s specialisation in chips and software.
CONTRIBUTION TO ELECTROMOBILITY
As the electrification of transportation continues to gain momentum, Qulectra is committed to innovation, safety and efficiency to align with the evolving needs of the EV industry. The joint venture addresses the unique challenges of EVs, such as wide dynamic range coverage, reliable short-circuit detection, and high electromagnetic compatibility (EMC) immunity.
The Q-Smart sensor, a digital marvel that combines intelligence and precision for highly accurate current measurement, is at the heart of Qulectra’s innovative offering. Designed to ASIL-D standards, the Q-Smart communicates seamlessly with the battery management system (BMS) via a controller area network (CAN) bus to determine the state of charge (SOC). This integration not only ensures highly integrated, redundant measurements in automotive and energy storage systems, but also provides economic benefits at the system level.
SENSING TOMORROW
The Q-Smart sensor features a 4-pin automotive connector for seamless integration, enabling digital signal transmission via a CAN2.0 interface. With built-in safety mechanisms up to ASIL-D standards, it ensures the highest level of safety for automotive applications. The Q-Smart sensor meets the dynamic requirements of EV applications with maximum measurement accuracy of less than 0.5%, a current measurement range of +/- 4000A and advanced integrated temperature compensation. It is available with a resistance value of 35µΩ and two different CAN connection directions on request.
The partnership between Wieland and Munich Electrification, embodied in Qulectra, not only demonstrates the transformative potential of strategic collaborations in the field of electromobility, but also highlights the key role of advanced shunt technology, as exemplified by the intelligent and precise Q-Smart sensor. Bringing precision and intelligence to current sensing technologies not only ensures the safety and efficiency of these vehicles, but also marks a significant step forward in the evolution of electromobility as the demand for electric vehicles continues to grow.
