Automotive

Elektro-Automatik Automotive Solution

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For battery systems in vehicles

The electrification of vehicles has pushed past consumer passenger cars into commercial and industrial transportation forcing automotive electronics to constantly evolve. While this technology area was once focused on entertainment, navigation, and comfort systems the industry has now turned its focus to higher power, higher voltages, and energy management systems.

This power is not just localized to a battery and electric motor, the drivetrain and power management systems also have similar power requirements. To be able to keep up with the changing demands of electric vehicles, the challenge for test engineers is to keep up with the trends and avoid buying new test equipment every few months.

EA Elektro-Automatik’s line of DC power supplies, electronic loads, and bidirectional power supplies have features that allow flexibility to test multiple devices and still meet future needs. EAs PSI, EL, ELR, and PSB product series can go up to 2000V, have true autoranging and on-board arbitrary waveform, and function generator.

This flexibility allows EA to produce or sink power needed to simulate or test any power device in an electric vehicle and the arbitrary waveform generator enables the user to simulate real-world conditions.

Power Supplies & Electronic Loads

High tech for research & development, industry, and education

EA Bidirectional DC Programmable Power Supplies

Conventional & regenerative power supply

EA Programmable DC Power Supplies

Benchtop & rackmount autoranging power supply

EA Programmable DC Electronic Loads

Conventional & regenerative loads

Application Solutions

Charge System
On-board chargers(OBC), Plug in charging systems and wireless chargers

One of the main questions when deciding to purchase an electric vehicle is how and where it will be charged. This question has the auto industry moving forward with different charging concepts to reduce the impact charging has on the driver. The trend appears to be moving towards higher voltages that requires smaller currents and less copper. While the industry decides on standards, testing of these concepts requires a versatile power supply that can meet low and high voltage requirements many of these chargers have.

EA’s line of DC power supplies with Autoranging capability can meet these changing demands.

EA Advantages:

  • Autoranging
  • Power Density
  • Battery simulation
  • Bidirectional and regenerative
  • Arbitrary waveform and function generator
  • Low EMC
  • Output voltage up to 2000V
  • Plug and play paralleling

Autoranging allows the user to get full power over a wide voltage range, rather than just at max voltage like traditional DC power supplies. EA also offers 1000V, 1500V and 2000V models that features high power density, bidirectional capability, function generators, regenerative capability, and very low EMC emissions to meet the ever-increasing requirements for EV charging systems.

DC-DC Converter Testing

DC to DC converters in electric vehicles are used to convert battery voltages (200-800V) to different DC voltages (12-48V) used by the headlights, radio and other ancillary equipment. Testing these devices requires a DC input and a load to connect the DC output to. EA’s line of power supplies and loads have low and high voltage options to meet these needs. EA’s bidirectional power supplies, the PSB 9000 and 10000 series can be used to source or sink voltage, enabling the test engineer to provide power both ways and minimize the test equipment needed.

The built-in function generator can be used to test real world situations, such as the headlights turning on and off repeatedly or turning on the heater full blast in the middle of winter.

EA Advantages:

  • Autoranging
  • Power Density
  • Battery simulation
  • Arbitrary waveform and function generator
  • Low EMC
  • Output voltage up to 2000V
  • Plug and play paralleling up to 2MW
  • High efficiency up to 96%

using a pair of PSBs to test both sides of the DC to DC converters. Due to the high efficiency of the PSBs, only 5-10% of the power is lost during these tests, with the remainder of the power regenerating back to the local power grid.

Traction Inverter Testing

In electric vehicles the motors are driven by AC current, but the majority of the vehicle is powered by DC. This makes sense since the source of power is a battery. To mitigate this traction inverters are used to convert power back and forth from battery and motor. Traction inverters are also used to support regenerative braking, boosting voltage and switch protection.

The PSB can both supply power to the traction inverter while simulating a battery and sink power when the motor turns into a generator to charge the battery during braking. EA’s autoranging feature provides a

EA Advantages:

  • Autoranging
  • Power Density
  • Battery simulation
  • Arbitrary waveform and function generator
  • Voltage models up to 2000V
  • Low EMC
  • Plug and play paralleling up to 2MW

flexible output range compared to traditional DC power supplies making the full power output available as the voltage output decreases. What that means is EA’s DC power supplies and loads can replace several traditional DC supplies that are normally needed to cover the higher voltage/lower current and low voltage/higher current operating points of the traction inverter.

Lights, Relays, Sensors and Accessory Testing

In addition to the major components of the electric vehicle, there are many other components in both EVs and combustion engine vehicles that also operate using DC power. Like many of the components in a vehicle, the voltages needed to power them can vary from the standard 12V up to 1000V or more. With so much variety test engineers are forced to acquire several traditional DC power supplies to test everything. EAs DC supplies and loads use a combination of high power density and autoranging to cover a much wider operating range and ultimately saving valuable rack space and cost. If cost is an important factor in your decision,

EA’s extremely high efficiency can save $1,000 or more per year just in energy costs.

EA Advantages:

  • Autoranging
  • Power Density
  • Battery simulation
  • Arbitrary waveform and function generator
  • Voltage models up to 2000V
  • Low EMC
  • Plug and play paralleling up to 2MW

Integration into an ATE is also simplified by using Anybus modules for digital communications with options such as CANopen, CAN, Ethernet, Profibus and more.

Fuel Cells, Batteries, and Battery Management System Testing

The power source for electric vehicles are batteries, fuel cells and battery management systems. With so much demand for power in all parts of the vehicle, it is imperative that batteries and fuel cells are tested by simulating real world conditions. Starts, stops, rush hour traffic in 100 degree heat with the AC are all situations the EV will encounter on the road and the ability to recreate these scenarios is required to meet various automotive test standards.

The built-in function and arbitrary waveform generator in EAs DC power supplies, loads and bidirectional DC supplies simplifies the process of simulating various driving conditions. Battery test features are also included to automatically charge or discharge a battery. The bidirectional capability of EA’s PSB series can accurately simulate a battery to test battery management systems without having to wait for a battery to charge or discharge to a specific state of charge.

EA Advantages:

  • Autoranging
  • Power Density
  • Battery simulation
  • Battery and fuel cell test functions
  • Arbitrary waveform and function generator
  • Voltage models up to 2000V
  • Low EMC
  • Plug and play paralleling up to 2MW

Battery Test

Fuel Cell Test

Battery Management System Test

GWInstek Automotive Test Solutions

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Automotive Charger and Battery Test Solutions

PEL-5000C Series
High Power DC Electronic Load

  • Maximum Power up to 192kW
  • Up to 8 units of Master/Slave Parallel Control
  • 5-digit Digital Voltage, Current and Power Meter
  • Large LCD Display
  • Display Voltage Value, Current Value, Watt Value at the Same Time
  • Suitable for Power Factor Regulator (PFC) Testing (600V, 1200V Models)
  • Automatically Perform OCP, OPP Test
  • The Power-on State Value Can be Set Constant Current, Constant Resistance, Constant Voltage, Constant Power, Constant Current + Constant Voltage, Constant Power + Constant Voltage, Dynamic and Short Circuit Modes
  • Short Circuit Time Can be Set During Short Circuit Test
  • Over Current, Over Power, Over Temperature Protection and Over Voltage Warning
  • Voltage Polarity Display Can be Set to Positive Value ("+") or Negative Value ("-")
  • Support Solar Panel MPPT Test
  • Optional Interface: GPIB, RS232, USB, LAN

AEL-5000 Series
AC & DC Electronic Load

  • Turbo Mode (Multiplier Mode) Can Withstand up to 2 Times the Rating Current and Power of the Electronic Load in a Short Period of Time
  • Operating Mode: CC, linear CC, CR, CV, CP and AC Rectifier Loads
  • Measurement Items: Voltage Value(Vrms, Vpeak, Vmax., Vmin), Current Value(Irms, Ipeak, Imax., Imin.), Watt Value, Volt-ampere Value(VA), Frequency Value, Crest Factor, Power Factor, Voltage Total Distortion(V THD, VH), Current Total Distortion (ITHD, IH), Etc
  • Eight Units Connected in Parallel up to 180kW for Single-phase and 540kW for Three-phase
  • Support Loading and Unloading Angle Control, Loading and Unloading Angle Control Can be set at the Full Range of 0-359 Degrees
  • Support Positive Half Cycle or Negative Half Cycle Load
  • Support SCR/TRIAC Current Phase Modulation Waveform, 90-degree Trailing Edge and Leading Edge
  • Support the Capacitive Load (Inrush Current) when the Power Supply is Turned on and the Transient Current (Surge Current) Test when the Load is Suddenly Connected (Hot Plug-in) During Operation
  • Crest Factor Range: 1.414~5.0
  • Power Factor Range: 0.1~1.0 Leading or Trailing
  • Frequency Range: DC, 40~440Hz(AEL-5003-480-18.75/AEL-5004-480-28: DC, 40~70Hz), and 800Hz and 1kHz Need to be Customized
  • Optional Control Interfaces: GPIB, RS-232, USB, LAN

Model Products Description Model Products Description
PSU 40-38 1500W 40V/38A DC Power Supply PSW 30-36 360W Auto-Range 30V/36A DC Power Supply
PEL-2004A 4-Slot Mainframe of DC Load GSP-9330 3.25GHz EMI Test Spectrum Analyzer Plus Free GKT-008 EMI Probe
MDO-2072EX 70MHz Mixed-Domain 5-In-One Oscilloscope MSO-2204EA 200MHz 4 CHS Mixed Signal Oscilloscope
GDS-207 70MHz Portable Oscilloscope plus PEL-3111 1050W DC Electronic Load
PEL-2040A Single Channel DC Load module (80V, 70A, 350W) GPT-9804 AC/DC/IR/GB 200VA Hi-Pot
MDO 2204EX 200Mhz 4ch Mixed Domain 5-in Oscilloscope GDS-3352 350MHz 2CHS Oscilloscope (5 GSa/S)
GDP-040D 40MHz Dual Channel Differential Probe (Isolation)

Automotive Waveforms

In order to meet the test requirements, GWINSTEK has included some related waveforms that are commonly used in accordance with ISO16750 road vehicles - electrical conditions and electrical testing for electrical and electronic equipment and ISO7637 road vehicles - electrical disturbances from conduction and coupling.

ISO-16750-2 Pretest with ASR-2000

The applications of electronic technology products are growing at a fast pace in our daily lives. Other than mobile phones, tablet computers or general consumer electronics, electronic technology products are also utilized in the automotive industry, including LED headlights / taillights, HUD (Head Up Display), adaptive front lighting, tire pressure monitoring system, ABS system, GPS, windshield wiper, AV system, etc. In order to ensure the safety of drivers and passengers as well as driving, vehicle manufacturers are required to have a higher product stability and stricter quality control standards for electronic devices installed in the automobile.

Vehicle driving process is an extremely harsh challenge for electronics manufacturers manufacturing automotive electronics. Rough-road driving, vibration from a piston-engine, electrical systems exposed to low or high temperatures, temporary exposure to unknown chemical mixtures, alternator overvoltage, and momentary drop in supply voltage all may cause the product to malfunction. Therefore, the environmental reliability requirements of automotive electronic products will be more rigorously regulated. At present, the ISO-16750 has been widely adopted and referenced by relevant automotive electronics manufacturers. ISO-16750 contains 5 parts. In addition to ISO-16750-1 General, the rest are ISO-16750-2 Electrical loads, ISO-16750-3 Mechanical loads, ISO-16750-4 Climate loads, and ISO-16750-5 Chemical loads. The sequence mode of ASR-2000 can arbitrarily edit the voltage test waveform, which is very suitable for generating the verification waveform of ISO-16750-2 Electrical loads.

Momentary drop in supply voltage by ASR-2000

Reset behavior at voltage drop by ASR-2000

Starting profile by ASR-2000

Load dump by ASR-2000

ASR-2000 for the applications of ISO-16750-2 verification items are as follows:

  • Direct current supply voltage
    ASR-2000 provides the maximum / minimum supply voltage to verify the DUT of a full range of 12V power supply system and the 24V power supply system.
  • Overvoltage
    ASR-2000 simulates the occurrence of overvoltage when the generator regulator fails.
  • Superimposed alternating voltage
    The internal resistance parameter requirements of the power supply is not considered. ASR-2000 collocating with a signal generator can simulate power output to have the frequency change from 1 to 999.9Hz.
  • Slow decrease and increase of supply voltage
    ASR-2000 sequence mode can simulate the battery being gradually charged and discharged.
  • Momentary drop in supply voltage
    Setting ASR-2000 power supply voltage to be interrupted instantaneously can simulate the effect caused by the melting of the conventional fuse component in another circuit. ASR-2000 can provide a minimum power interruption output of 100us.

  • Reset behaviour at voltage drop
    ASR-2000 can flexibly set different voltage drop times to test the reset behaviour of the DUT.
  • Starting profile
    The starting profile generated by ASR-2000 can verify the characteristics of the DUT during and after the car ignition.
  • Load dump
    Load dump is generated when the battery powering the generator or inductive component is instantaneously disconnected. If the parameter requirements of the input impedance of the power supply are not considered, editing the ASR-2000's sequence mode can obtain the waveforms of ISO-16750 test A and test B.
  • Reversed voltage
    ASR-2000 reversed output can meet the verification requirements of various automotive electronic products.

C-1100 Multi-Channel ASK/FSK Tester

C-1100 is the world’s first first ASK/FSK communications tester and first dedicated professional tester for TPMS automatic production. It provides two signal output channels, including 315/433 MHz and LF 125 kHz and four RF input channels. The tester integrates all production tests for TPMS Sensor/Monitor. Four-channel design, a dedicated PC software and the custom-made adjustment function can increase production efficiency by three folds, and reduce equipment costs by 50%~70%.

C-1100 not only tests RF Tx and Rx but also “ wakes up” device. The C-1100 provides a complete PC software. In addition to the tests required for ASK/FSK, C-1100 also provides production debug analysis during production line testing, FCC, ETSI test specifications, and supports the corresponding LabVIEW program.

GWInstek LinkView software for Battery Charge and Discharge Test

Battery Charge & Discharge Test with LinkView

GW Instek introduces LinkVIeW software to allow users to quickly set test instruments for the operation of charging and discharging tests on battery and super capacitor, etc. Users can define charging and discharging procedures to automatically execute procedures so as to obtain measurement results. History graphs are available & they can be exported to Excel for further analysis.

Features of LinkVIeW

  • Long Term Power Monitoring of I, V, P(W)
  • Support Data Logging(option) and .CSV File Exporting
  • Create/Define Operation Sequence for Controlling Source/Load Behavior
  • Easily Edit The Test Files Including Reading Record, Save Record and Delete Record
  • Simultaneously Run Test Sequence of Each Channel & Waveform Display
  • Maximum Allocation of 12 Channels for Charging & Discharging Test

  • Supported Languages Include Japanese, English, Chinese(Traditional) or Chinese(Simplified)
  • Data Analyzer:
    VIeW Chart: Supports Zoom In/Tracking of Samples
    VIeW Table: Summaries Testing Result for VIeW and Each Step Includes
  • Voltage/Current/Power/VMax/Imax/PMax/AmpHour
  • Live Data Monitoring:
    VIeW: Self-defined Display Range/Offset Adjustable
    Controllable Displayed Curve

Automotive test solution - power supply regulation LV148

With the popularization of automotive electronic products, the five major European car manufacturers: Audi, BMW, Mercedes, Porsche and Volkswagen have jointly upgraded the power system for cars to 48V, which also gave birth to the LV 148 regulation for automotive power systems. With respect to the LV148 regulation, GW power supplies provide effective verification solutions for R&D and quality assurance units in LED headlights, ECU, wiper motors, power windows, car audio, GPS, chargers and other automotive electronic products.

  • Support Data Logging(option) and .CSV File Exporting

    There are many voltage variation tests in the LV148 evaluation test. ASR-2000 cannot deal with the high-speed voltage variation test of up to 300kHz sine wave specified in the "Superimposed AC Voltage" of E48-05, and can be used with conventional DC stabilized power supplies to handle difficult millisecond-level voltage variation tests*

    The ASR-2000 series

*Depending on the test conditions and load (DUT), some items may not be supported.

  • Ideal for software engineers (below 100W)
  • Ideal for circuit designers/experimental researchers/reliability testers (100W~1600W)
Software engineers require that drive control boards and developed products are compatible with the existing 12V and LV148 to ensure that the products operate in a stable manner. The 48V electrical equipment in LV148 includes "pump", "air conditioner", "motor", "heater", "EPS", "inverter" and drive system. The drive power ranges from several hundred watts to several kilowatts or even higher. The PSW series with power up to 1kW and the PSB-L series up to 1.6kW can be used to evaluate many electrical components, including existing 12V products.

The PFR series

The PSW series


The PSB-L series

Toellner General Configuration for Automotive Transient Testing

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  • 4-Quadrant Amplifier to simulate automotive transients TOE-7621-32
  • Wavecontrol PC Software for controlling timing and sequence of waveforms TOE 9700
  • NI-DAQ Card TOE-9217
  • Micro-Switch for fast interruptions TOE-9261-50/100
  • DC Power Supply TOE-8870
  • Reference Resistors TOE-9260/100
  • Rack 19” HU including power on module and fixing material

Software WaveControl

The Software Wavecontrol provides waveforms and controls the TOELLNER system components at the test station, which can be individually tailored to your requirements.

Using a DAQ-Card, any signal waveform can be provided with Arbitrary Power Supplies or 4-Quadrant Amplifiers with outputs from 160 W to 5200 W.

For fast interruptions, TOELLNER offers electronic switches with switching times below 500 ns.

The Software WaveControl provides extensive Waveform Libraries for Normative Tests, e. g.

- LV 124, LV 148
- VDA 320
- VW 80000
- VW 82148

- GMW 3172
- MBN 10615
- ISO 16750-2

  • Separate Voltage and Current Scale
  • SImport and Export of recorded Data
  • SVisual Generation of individual Waveforms
  • SSequence Controlling and Timing