An EMC-safe data acquisition at 3,500 volts and a decentralized testing approach

Precisely Capture Measurement Data An EMC-Safe Data Acquisition at 3,500 Volts and a Decentralized Testing Approach

2026-08-10 A guest post by Felix Lukasch* | Translated by AI 3 min Reading Time

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The electrification of a 240-ton truck pushes the boundaries of power electronics. To safely validate drive systems with a system performance of up to 6 MW, Liebherr has created a test environment that surpasses conventional test bench architectures. The decentralized acquisition of over 900 measurement channels under EMC strain plays a significant role.

At the test bench, data from approximately 240 analog channels is measured. In total, including the channels captured via CAN, around 900 channels are recorded and monitored at the test bench.(Image: Liebherr) — At the test bench, data from approximately 240 analog channels is measured. In total, including the channels captured via CAN, around 900 channels are recorded and monitored at the test bench.
(Image: Liebherr)

In open-pit mining, extreme conditions prevail—not only for the construction machinery materials but also for the drive technology. When Liebherr develops a battery-electric mining truck weighing 240 tons, the reliability requirements for the components are extremely strict.

The electric drivetrain must operate in the megawatt range while withstanding vibrations, dust, and extreme temperatures. To shorten the development time of such a high-performance machine, Liebherr is shifting validation into a controlled laboratory environment. For this purpose, a new test hall with a floor area of 900 m² (approx. 9.688 sq ft) has been constructed at the Liebherr-Electronics and Drives site, specifically designed for the analysis of high-voltage large drives.

Thermal and Electrical Limit Ranges

Image 1: The hall built specifically for the test bench has a floor area of 900 m² (approx. 9.688 sq ft).(Image: Liebherr) — Image 1: The hall built specifically for the test bench has a floor area of 900 m² (approx. 9.688 sq ft).
(Image: Liebherr)

The project is technically complex, as becomes apparent when looking at the performance data. The main drivetrain requires validation at up to 3.6 MW of power and voltage levels reaching up to 3,500 V, far exceeding what is typical in the automotive sector. Background: The truck's rated power is 2 MW, with bursts of up to 3.6 MW possible for periods of less than two minutes. Additionally, auxiliary drives and onboard power supplies (Auxiliary Power Supplies) alone reach the power output of a small town charging station at 500 kW.

A critical aspect of development is thermal management. To ensure the lifespan of the expensive traction batteries and power electronics, the cooling systems must be tested under real load conditions. The test bench simulates this with powerful air cooling systems capable of a throughput of 4 m³/s (approx. 141,3 CFS), with the intake air artificially preheated to 55 °C (131 °F) to represent deployment in hot climates. At the same time, water cooling systems handle heating and cooling capacities in the high triple-digit kilowatt range. The energy flows must be measured with high precision and synchronized to optimize the overall efficiency of the system.

Electromagnetic Compatibility

Image 2: Liebherr was able to shorten the development time of its mining trucks. One example is the T264 BET truck. This was made possible by decentralized data acquisition close to the sensor.(Image: Liebherr) — Image 2: Liebherr was able to shorten the development time of its mining trucks. One example is the T264 BET truck. This was made possible by decentralized data acquisition close to the sensor.
(Image: Liebherr)

The biggest hurdle for precise data acquisition in such an environment is electromagnetic compatibility (EMC). The immense currents and high-frequency switching operations of the converters induce interference signals that would make conventional analog measurements via long cable runs impossible. Liebherr addresses this issue together with imc Test & Measurement through decentralization.

Instead of transmitting signals analog to a central control room, signal conditioning and digitization take place directly at the sensor. The modular units of the CRONOSflex and CANSASflex series developed by imc are located spatially close to the components of the drivetrain. This minimizes the analog cable lengths and, consequently, the potential for interference.

For the particularly critical temperature measurement inside the electric motors, Liebherr takes it a step further: non-conductive fiber optic sensors are used here. Since these sensors are based on optical principles, they are galvanically isolated and immune to electromagnetic fields.

In the planning and development of a test bench of this size, we rely on the support of our partners. By involving imc early in the planning phase of the test bench and through their competent support and advice in selecting the appropriate measurement systems, a solution was realized that ensures both the reliable acquisition of all necessary measurement data and the capability to control the test bench.

Felix Lukasch, Head of the Biberach Test Center at Liebherr-Electronics and Drives.

900 Measurement Channels from 240 Sensors

The sheer volume of data, with over 900 channels supplied by around 240 analog sensor data and complex fieldbus information via CAN, requires a powerful software architecture. Using the imc STUDIO platform, Liebherr not only controls data acquisition but also integrates third-party systems, such as high-precision power analyzers for electrical power calculation.

This openness of the system is crucial, as test requirements can constantly change over the course of a project. Additionally, there is the option to modularly expand the measurement system or define new interfaces via software. This allows developers to respond flexibly to new insights gained during the prototype phase. The result is a comprehensive validation "from the battery to the wheel," identifying sources of error long before the first truck hits the field. (heh)

*Felix Lukasch is Head of Test Center Biberach at Liebherr-Electronics and Drives.

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