Your Path to Better Energy Efficiency: Current Mapping

Velizara Lilova · 19.03.2025

Automotive | Data Acquisition | Power Electronics · 5 min. reading duration

How can you optimize the energy efficiency of EVs and Internal Combustion Engine vehicles?

Discover how precise current mapping and compact sensor design are revolutionizing automotive testing. Accurately measuring current consumers in a vehicle is crucial for enhancing performance, reliability, and energy management. Based on this critical data, engineers can identify inefficiencies and optimize the vehicle's electrical systems, leading to better fuel economy and extended driving ranges.

Your Path to Better Energy Efficiency: Current Mapping

Velizara Lilova

Product Manager Data Acquisition, HIOKI Europe

Figure 1 Current Mapping: analyze your electrical system

Current Mapping for Vehicle Efficiency

Drivetrain and battery efficiency are in the focus of automotive engineers but there is more you can do. Optimizing the overall energy efficiency of all electrical systems is a highly effective approach to increase reach and reduce the number of charging intervals. But this is a challenge for all engineers: where to start? Understand your energy consumption and eliminate inefficiencies with current mapping.

Current mapping refers to the detailed recording and analysis of current flow across the great number electrical consumers within the vehicle from assistance systems to the multimedia system. Effective current mapping is essential for improving the electrical system performance in complex systems like modern EVs and ICE vehicles as it helps identify patterns, potential overloads, and energy-saving opportunities.

Figure 2 Size does matter: ultra-compact sensors make measurements easy

High Precision Current Logging. Ultra Compact

HIOKI has designed an innovative multi-channel current measurement solution specifically for development and evaluation teams in the automotive sector. It allows for the precise measurement and logging of even the smallest currents in the vehicle’s electrical systems. Easy-to-install ultra-compact current sensors and wireless data transfer allow for flexible installation in confined spaces. This setup provides engineers with valuable data that helps them significantly improve energy efficiency, which ultimately leads to enhanced performance and extended driving range of vehicles.

Highly Accurate Current Measurement

Accurate current measurement of all consumers in automotive electrical systems requires sensors with very high precision even for low currents. HIOKI’s new AC/DC zero flux current sensors CT7812 (2 A) and CT7822 (20 A) allow engineers to measure currents with an impressive accuracy of ±0.3 percent. With this high precision and a minimum resolution of 0.1 mA, development engineers can retrieve accurate consumption data of low currents, allowing them to optimize energy consumption, contributing to extend operating times and increase the driving range of EVs.

Ultra-Compact Sensors for the Narrowest Spaces

Measuring built-in current consumers is challenging in vehicles due to confined spaces, which limit both the placement and operation of measurement equipment. With a total length of only 7.65 cm and a sliding mechanism the new ultra-compact sensors can be easily connected to consumers – even with one hand. This enables precise probing even in tight spaces such as engine compartments, enclosures, fuse boxes and they even work under extreme temperatures.

Figure 3 Measuring with precision, reliability and convenience

From Alaska to the Sahara: Reliable Long-Term Logging

The sensors' fluxgate technology offers reliable temperature compensation, ensuring stable measurements even under varying temperature conditions, ranging from -40° C to +85° C. This reliability is crucial for long-term measurement accuracy in automotive applications.

Getting the whole picture: 55 Measurement channels with one set up

For effective and precise current mapping, the system the system consisting of the Data Logger LR8450-01 and the new current modules LR8536 and U8556 provides up to 55 current measurement channels. This allows simultaneous measurement of multiple current consumers in complex electrical systems such as EVs, trucks, construction vehicles, or agricultural machinery. The instrument is not limited to current measurement though. The versatile data logger is a mix & match system that can log signals like temperature, strain, vibration, humidity, resistance, voltage, CAN signals and many more. With up to 330 channels, engineers can comprehensively summarize all parameters of their devices under test (DUT) in one instrument.

Wireless Connection for Enhanced Flexibility

Another highlight of HIOKI's multi-channel current measurement solution is the flexibility of a wireless connection. The LR8450-01 is the first data logger to use wireless modules. Separating the main unit from the measurement modules and sensors allows for more flexibility as the logger can be kept on the seat or even outside the vehicle while measurements at various locations are executed. This feature saves time and provides development teams with more flexibility in their setups.

Figure 4 55 channel data management in one system

Get the Most from Your System

There is always room for more gains of efficiency for both EVs and ICE vehicles. It is essential to know where these gains can be won and to what extent. Precise measurement of current consumers in automotive systems allows to make the right conclusions to optimize energy efficiency and enhance performance. The multi-channel data logging system LR8450 with compact sensors specifically developed for use in the automotive industry is an effective tool to get the job done.

LR8450

LR8450 - Modular multi-channel Data Logger

Multi-channel data logger, connect up to 4 plug-in modules with up to 120 analog channels, max. 1 ms update interval, max. 100 VDC, 8 inputs for pulse/logic/rotational speed, 7“ TFT-Display, GigabitLAN und USB / SD card, optional battery operation

€1,818.00*

LR8450-01

LR8450-01 - Wireless modular multi-channel Data Logger

Wireless multi-channel data logger, connect up to 4 plug-in and 7 wireless modules for max. 330 analog channels, max. 1 ms update interval, max. 100 VDC, 8 inputs for pulse/logic/rotational speed, 7“ TFT-Display, Gigabit-LAN und USB / SD card, optional battery operation Banner Specs Wireless LAN capability Up to 330 analog channels with plug-in and wireless modules and 8 pulse/logic inputs Voltage, current, temperature, humidity, resistance, heat flow, strain, pulse, CAN and CAN FD input and output Max. 1 ms update interval Optional battery operation USPs Maximum flexibility and high accuracy with wireless modules and real-time data transfer via Wireless LAN High-speed data recording with up to 1 ms Up to 330 analog channels and up to 55 current channels High-precision current logging with dedicated HIOKI current sensors CAN and CAN FD data input and output and measurement of strain, stress and heat flow Applications Current consumption in Electric Vehicles (EVs) Logging of voltage, current, temperature, resistance, vibration and strain during product development and production Long-term observation of stray currents in metro railway stations Observation of voltage, temperature and temperature distribution in Light Duty, Heavy Duty, construction and agricultural machinery (and data output via CAN) Process observation with heat flow sensors Measurement of temperature and heat flow for quality control, e.g. food processing Thermal Runaway of EV batteries Monitoring and maintenance of industrial equipment Observation of temperature and humidity for environmental and climate studies In detail:The modular LR8450-01 Data Logger is a highly versatile and adaptable solution, built for professionals who require both speed and scalability. This high-speed, multi-channel logger supports up to 120 channels through four plug-in modules, and with the addition of seven wireless modules, the maximum number of channels expands to 330. These wireless modules can be positioned in confined spaces or near the device under test, significantly reducing efforts and enhancing the measurement accuracy. The recorded data is transmitted via wireless LAN to the logger and can be monitored in real-time. The LR8450-01 features a 16-bit analog-to-digital converter (ADC) for enhanced measurement precision, and all modules that can be connected to the LR8450-01 are capable of handling direct voltages up to 100 V, with an isolation to earth of 300 V DC/AC, CAT II. Seven different module types are available for capturing data such as voltage, current, temperature (thermocouples or Pt100/1000), humidity, resistance, strain, pulse, and CAN (FD). HIOKI current sensors enable high-precision AC/DC current logging from 2 A to 6000 A, supporting up to 55 directly connected current sensors. Its 1 ms recording interval is ideal for capturing fast-changing signals, while the 7" TFT display provides clear, real-time data visualization for easy on-site monitoring. With the flexibility to run for hours on battery power, the LR8450-01 ensures continuous logging for both stationery and mobile testing. Data can be stored on SD cards or USB sticks, and retrieval is made easy through its Gigabit-LAN connector. The logger also features a DC input for additional supply power flexibility. If no wireless modules are used, the logger can be controlled wirelessly from a PC, allowing it to be placed in restricted or hard-to-access areas. Whether monitoring electric vehicles or managing complex industrial systems, the LR8450-01 sets the standard for precision and adaptability in data logging.

€2,158.00*

LR8536

LR8536 - 5-channel wireless logger module for current sensors, 1 ms

5-channel wireless interface and signal conditioning module for the LR8450-01 Data Logger to connect HIOKI Current Sensors with a PL14 connector Banner Specs:5 input channels with individual signal conditioning 1 ms simultaneous update interval Battery-powered wireless operation in tight spaces Operating temperature -20 oC to 55 oC Up to 7 modules can wirelessly connect to one LR8450-01 Data Logger Can be combined with a large variety of current sensors from 2 A to 6000 A USPs: Individual scaling for each current sensor Current logging from 100 µA to 2 kA DC in one device Up to 35 channels current logging with 1ms update interval High-voltage Electric Vehicle (EV) battery current logging and low power circuit current logging possible with a single device Compact size and wireless capability, perfect for use in confined spacesApplications: Development and analysis tool for improving the fuel efficiency of EV Consumption monitoring of EV high-voltage batteries and low-voltage circuits like power steering, seat heating, interior lighting etc. Optimizing the overall energy consumption of EVs to extend the driving rangeOptimizing the overall energy consumption of electric construction vehicles or electric agricultural vehicles to extend the time between chargingIn detail: The LR8536 Wireless Current Module is the interface between up to 5 clamp-on current sensors and the LR8450-01 Data Logger. Each current sensor input has its own signal conditioning which makes it possible to have individual scaling and simultaneous 1 ms recording. The module is exclusively designed to add current logging functionality to the highly versatile LR8450-01 Data Logger. Up to seven LR8536 modules can be connected wirelessly to a single LR8450-01 Data Logger. The module can be used with the ultra-compact yet high-precision current sensors CT7812 and CT7822 as well as with a variety of other HIOKI current sensor types reaching from 2 A to 6 kA. These can be used in any combination in accordance with the application and test requirements, providing extended usability of the data logger. All temperature-compensated HIOKI current sensors with a PL14 connector are suitable to be used in combination with the new LR8536 wireless current module.

€1,858.00*

U8556

U8556 - 5-channel logger module for current sensors, 1 ms

5-channel plug-in interface and signal conditioning module for the LR8450 Series Data Logger to connect HIOKI Current Sensors with a PL14 connector Banner Specs: 5 input channels with individual signal conditioning 1 ms simultaneous update interval Operating temperature -20 oC to 55 oC Up to 4 modules per LR8450 Series Data Logger Can be combined with a large variety of current sensors from 2 A to 6000 A USPs: Individual scaling for each current sensorCurrent logging from 100 µA to 2 kA DC in one device Up to 20 channels precision current logging with 1 ms update intervalHigh-voltage Electric Vehicle (EV) battery current logging and low power circuit current logging possible with a single device Applications: Development and analysis tool for improving the fuel efficiency of EVs Consumption monitoring of EV high-voltage batteries and low-voltage circuits like power steering, seat heating, interior lighting etc. Optimizing the overall energy consumption of EVs to extend the driving range Optimizing the overall energy consumption of electric construction vehicles or electric agricultural vehicles to extend the time between charging In detail:The U8556 Current Module is the interface between up to 5 clamp-on current sensors and the LR8450 Series Data logger. Each input channel has its own signal conditioning which enables individual scaling and simultaneous 1 ms recording. It is exclusively designed to add current logging functionality to the highly versatile LR8450 Series Data Loggers. Up to four U8556 modules can be connected to a single LR8450 Series Data Logger.The module can be used with the ultra-compact yet high-precision current sensors CT7812 and CT7822 as well as with a variety of other HIOKI current sensor types reaching from 2 A to 6 kA. These can be used in any combination in accordance with the application and test requirements, providing extended usability of the data logger. All temperature-compensated https://www.hioki.com/euro-en/products/multichannel-data-loggers/multichannel/id_1266366 HIOKI current sensors with a PL14 connector are suitable to be used in combination with the new U8556 Current Module.

€1,318.00*

CT7812

CT7812 - AC/DC Current Probe

Ultra-small, zero-flux clamp-on AC/DC Current Probe using flux gate detection, high accuracy ±0.3 %, max. resolution 0.1 mA, wide temperature range -40 to 85 °C, measurable current up to 2 A, designed exclusively for LR8450 Series Data Logger

€1,268.00*

CT7822

CT7822 - AC/DC Current Probe

Ultra-small, zero-flux clamp-on AC/DC Current Probe using flux gate detection, high accuracy ±0.3%, max. resolution 1 mA, wide temperature range -40 to 85 oC, measurable current up to 20 A, designed exclusively for LR8450 Series Data Logger

€1,268.00*