{"id":18052,"date":"2025-08-19T11:13:21","date_gmt":"2025-08-19T09:13:21","guid":{"rendered":"https:\/\/www.tcs-engineering.de\/equipotential-bonding-in-the-ev-high-voltage-system-what-you-need-to-know-about-this-core-element-of-electrical-ev-high-voltage-safety\/"},"modified":"2025-10-19T11:39:54","modified_gmt":"2025-10-19T09:39:54","slug":"equipotential-bonding-in-the-ev-high-voltage-system-what-you-need-to-know-about-this-core-element-of-electrical-ev-high-voltage-safety","status":"publish","type":"post","link":"https:\/\/www.tcs-engineering.de\/en\/equipotential-bonding-in-the-ev-high-voltage-system-what-you-need-to-know-about-this-core-element-of-electrical-ev-high-voltage-safety\/","title":{"rendered":"Equipotential bonding in the (ev) high voltage system: What you need to know about this core element of electrical (ev) high voltage safety"},"content":{"rendered":"

\ud83d\udd0c Equipotential bonding in high-voltage systems: what you need to know about this core element of high-voltage electrical safety<\/strong><\/h2>\n

Equipotential bonding in the (ev) high voltage system<\/strong> is a central element of electrical safety in high-voltage vehicles. In every well-founded (ev) high voltage training course<\/strong><\/a> training, the measurement of equipotential bonding is therefore a mandatory component – both within HV (ev) components<\/strong> and between different high-voltage components<\/strong> of an electric vehicle. <\/p>\n

\ud83d\udd0d What is measured?<\/h3>\n

Specifically, it is about the electrical resistance between the conductive housings<\/strong> of any two (ev) high voltage components. This so-called equipotential bonding resistance<\/strong> is measured using a milliohmmeter<\/strong> based on the precise four-wire measurement<\/strong> – not to be confused with the three-wire measurement for grounding resistance measurement. <\/p>\n

\ud83d\udccf Legal requirements according to UN ECE R 100<\/h3>\n

According to section 5.1 of UN ECE R 100<\/a><\/strong> the resistance between two exposed conductive parts must not exceed 0.1 Ohm<\/strong>. This is a very strict regulation – with good reason. <\/p>\n

\u26a0\ufe0f Safety in the event of a fault<\/h3>\n

The HV on-board electrical system<\/strong> of modern electric vehicles is an IT-like network<\/strong> in which HV+ and HV- are galvanically<\/strong> isolated from the vehicle ground<\/strong> and the operating equipment. This means that there is no dangerous current flow in the event of a single short circuit<\/strong> (e.g. HV+ to earth). <\/p>\n

However, high-voltage safety<\/strong> should also work reliably in the worst-case scenario<\/strong>:
If a second short-circuit<\/strong> occurs (e.g. HV (ev) at another point), a short-circuit current<\/strong> is generated that must flow via the equipotential bonding and safely trigger<\/strong> the HV fuse<\/strong>. Prerequisite: The equipotential bonding is functional and sufficiently resilient. <\/p>\n

\ud83d\udee0\ufe0f Further task: Fault detection through insulation monitoring<\/h3>\n

Functioning equipotential bonding is also a prerequisite for the insulation monitor<\/strong> to be able to detect faults anywhere in the vehicle – even if insulation monitoring only takes place at one point. Equipotential bonding electrically connects all housings with each other – and therefore enables faults to be detected in good time. <\/p>\n

\n

\ud83c\udf93 Conclusion:<\/h2>\n

Equipotential bonding in the high-voltage system<\/strong> is more than just compliance with standards<\/strong> – it is an active protective measure on which the entire safety concept of an electric vehicle is based. No wonder that measuring equipotential bonding is a standard part of every high-quality (ev) high voltage training course<\/a>. <\/p>\n

Equipotential bonding thus fulfills central safety tasks in the (ev) high voltage vehicle and is therefore so important in high voltage training courses<\/a>. PS: Our recommendation:<\/strong> Our free<\/strong>(REALLY<\/strong> free, even WITHOUT having to provide an email address!) paper “6 things you need to know in advance about the high-voltage qualification of your employees” is available here (click). <\/a> <\/p>\n<\/div><\/div><\/div><\/div><\/div>\n","protected":false},"excerpt":{"rendered":"","protected":false},"author":5,"featured_media":17904,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[3],"tags":[],"class_list":["post-18052","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-unkategorisiert"],"yoast_head":"\nPotential equalization in the (ev) high voltage system - TCS-Engineering<\/title>\n<meta name=\"description\" content=\"Equipotential bonding in the (ev) high voltage system as a central aspect of electrical safety and how it works.\" \/>\n<meta name=\"robots\" content=\"index, follow, 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