Crash test monitoring of electric vehicles

Display, control, and analyze live measurements safely via remote and app

Electric and hybrid vehicles need to be sustainable, eco-friendly and, most importantly, safe – even in the unfortunate event of an accident. Different from combustion engine vehicles, the body of electric or hybrid vehicles may be energized after a crash. A sudden fire caused by the battery is another dangerous risk. Such life-threatening situations for passengers and rescue workers must be avoided.

The challenge

In order to minimize the risk of fire or electric shocks, many automotive manufacturers verify the reliability of the respective safety mechanisms with crash tests.
These tests focus on the insulation monitors which access the HV and battery system and de-energize them in case of a crash. Moreover, the temperature development of the vehicle battery is monitored to prevent a fire.



  • 1 to n vehicle CAN buses
  • ECU protocols XCP and CCP
  • Automatic remote data transfer to the data base
  • Event-triggered MDF4 storage
  • Wireless display of the live measurement data before, during, and after the crash

The solution

The data logger IPEhub2 is used to monitor the safety mechanisms immediately after the crash. It records the CAN bus data of the HV and battery system and transfers it to the test engineers’ measurement computer via WiFi interface for live display. If all safety mechanisms work ideally, the insulation monitor will be triggered and the HV system will be de-energized.

In the further course of the test, the IPElog2 will monitor the temperature development of the vehicle battery. The gradient of the temperature rise as well as the maximum temperature of the battery will be calculated. If an error occurs or defined limits are violated, an alert will be triggered via digital outputs or e-mail.

If high-frequency analog variables become relevant in test requirements - in addition to the bus data - the IPETRONIK X modules with up to 400 kHz can be used, for example. This is also possible for requirements in the HV range.

The advantages

Safety first – with the IPEhub2, your team can monitor the crash test wirelessly and therefore safely. They do not need to be on site for the second IPElog2 phase either. In case of a limit violation, the alert function will allow them to intervene in time.

  • Recording of 1 to n CAN bus networks
  • Independent data storage
  • WiFi and MQTT interface for online view (with the IPEmotion software)
  • Wireless connection to mobile devices (via the IPEmotion app)
  • External alert via digital outputs and/or e-mail

Contact person

Your contact for support questions

+49 7221 9922 333

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