As electric vehicles grow in popularity, rigorous testing of on-board chargers (OBC) under different grid conditions is vital to ensure safe operation over batteries’ lifetimes. It directly affects the charging efficiency and the vehicle’s battery life.
Traditional methods struggle to simulate complex power network dynamics. Therefore, regenerative grid simulator solutions emerge with the ability to simulate various power grid conditions to provide a controllable testing environment for on-board chargers.
Their four-quadrant operation facilitates realistic simulation of diverse grid scenarios. It allows thorough on-board charger evaluation under all circumstances to verify stable charging functionality and robust protections!
Why is the OBC Test Important?
The on-board charger serves a vital role in electric vehicles. It governs the charging process by converting AC power from the electric grid to DC power used to recharge the vehicle’s battery pack.
OBC also provides necessary protection functions during the charging process, such as over-voltage, under-voltage, over-current, and under-voltage. OBC can cut off the power supply in case of abnormalities to ensure the safety of the charging process.
Rigorous testing of the OBC ensures automotive performance under different working conditions, such as charging efficiency and performance under different charging modes.
By simulating various power grid faults, OBC testing can help detect potential issues and improve the safety of electric vehicles. Correspondingly, this analysis data can also guide performance improvement plans.
What are the Functions of a Regenerative Grid Simulator?
A regenerative grid simulator aims to simulate various electric grid scenarios essential for assessing OBC performance.
1. What is a Regenerative Grid Simulator?
The regenerative grid simulator is an advanced piece of testing equipment. It can simulate the AC power grid under normal or fault conditions to test the performance of power electronic devices under different power supply states.
For example, it can set the grid voltage, current, and frequency as needed to verify the performance of electronic power equipment under these conditions.
2. Test Scenarios for the Regenerative Grid Simulator
A regenerative grid simulator is well-suited for comprehensive OBC evaluation.
1) OBC Charging Status
In the OBC charging status, the power grid simulator provides standard AC power to the OBC to test its ability to convert AC power into DC power and charge the electric vehicle battery. It can test:
- Charging efficiency, rate, and stability at different voltages and frequencies
- The protection function of the OBC in cases of abnormal power grid input
- Simulate various charging scenarios, such as fast charging and regular charging, to analyze the compatibility of OBC
2) OBC Inversion Status
In the OBC inversion status, this test simulates the process of the OBC inverting the DC power in the EV battery into AC power and transmitting it back to the power grid. It can test:
- Inversion efficiency
- Performance under different load conditions
- Stability and reliability of electricity transmission, etc.
3) DC-DC Electrical Performance
The function of a DC-DC converter is to convert high-voltage direct current in the battery into low-voltage direct current that electronic devices can use. It protects devices from damage caused by high voltage. The regenerative grid simulator is used to verify:
- The stable voltage output capability of the converter
- Adjustment ability during voltage fluctuations, etc.
4) Protection Tests
These tests detect whether abnormalities like over-current, over-voltage, or temperature thresholds trigger certain safeguards. These include shutdowns, reduced output, etc.
Rigorous fault testing reinforces robust protections and prevents hazardous OBC operation in fault scenarios to uphold passenger and vehicle safety.
ActionPower’s PRE20 and OBC Test Solutions
As a leading provider of professional programmable power supply and test equipment solutions, ActionPower has been dedicated to electric power technology R&D for many years. We have accumulated several core technological achievements in areas like electric power conversion and control.
Our products, like power grid simulator solutions, are widely applied in fields such as new energy generation and electric vehicles. Here is our PRE20 + OBC test solution, which has been displayed at the Automotive Testing Expo in Germany:
1. PRE20 Regenerative Grid Simulator
Our PRE20 regenerative grid simulators are applied to normal power tests and power grid-related tests. They are full 4-quadrant, full-regenerative AC power sources designed for common electrical power testing scenarios. Features include:
- Integrated bidirectional programmable AC power supply and feedback programmable AC load in one unit
- Flexible 12 RLC network models simulate linear loads to fully verify the performance of the tested product under different impedance, three-phase balance, and unbalanced load modes
- Current and power limits ensure safety
- 10 kHz–2 kHz bandwidth and 60 μs delay for realizing power hardware in the Loop (PHIL) simulation
- Integrating internal R and L impedance adjustments
2. Electric Vehicle OBC/DC-DC Testing System
This solution is specifically used to verify the input/output characteristics of OBC and DC-DC converters. The PRE20 regenerative grid simulator and DC power source feature parallel expansion interfaces. This solution features:
- Meet the testing needs of OBC and DC/DC and balance signal and power-level testing
- Integrated source and load simplify system configuration
- Compact 20kVA AC and 30kW DC units maximize lab space
- Customizable independent software allows for custom templates and permissions
- Automated one-click reporting in standard formats streamlines submissions
Conclusion
Overall, regenerative grid simulator solutions enable comprehensive evaluation of on-board chargers under grid dynamics. As EVs rise in adoption, such testing becomes critical.
ActionPower’s PRE20 and OBC test solutions, which are displayed at the Automotive Testing Expo in Germany, streamline the process. Features like flexible programming and automated workflows improve efficiency. Precise OBC testing ensures EVs charge dependably over many years and further promotes electrification progress. Contact us for more information about the OBC test solution!
