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.
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
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.
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 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.
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.
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
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.
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.
Integration into an ATE is also simplified by using Anybus modules for digital communications with options such as CANopen, CAN, Ethernet, Profibus and more.
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.
High Power DC Electronic Load
AC & DC Electronic Load
|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)|
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.
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:
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.
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
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.
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.
|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
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