Test technology for OBC, DC/DC converters, BMS and HV components
Programmable AC and DC sources, high-power DC power supplies, electronic loads, bidirectional source-sink systems, battery cell simulators and software solutions for the development, validation and production testing of electrified vehicles.
OBC test with grid simulation and battery simulation
Realistic electrical conditions for development, validation and production
Electrified vehicles place high demands on test technology. In addition to voltage and current, dynamics, energy regeneration, safety, interfaces and reproducible test sequences are decisive.
From single instrument to complete test bench
ET System supports the selection of suitable AC/DC test equipment and the integration of complete test systems. Depending on the application, AC sources, regenerative grid simulators, high-power DC sources such as LAB/HP, electronic loads, bidirectional source-sink systems such as N35500 and software can be combined.
For OBC, DC/DC, BMS, inverters and HV components
Typical applications include on-board charger tests, DC/DC converter tests, BMS HIL tests, battery pack tests, charging infrastructure, inverter validation, endurance testing, burn-in and automated end-of-line testing.
Test setups for OBC, DC/DC converters, BMS and HV components
The following test tasks represent typical requirements in automotive and e-mobility projects.
On-board charger test
The AC input side is supplied by a programmable AC source or a regenerative grid simulator. On the DC side, a bidirectional DC source/sink or electronic load simulates the vehicle battery. This allows charging profiles, grid influences, efficiency, protection functions and operating limits to be tested.
DC/DC converter test
Input and output are supplied or loaded under controlled conditions. For higher voltages and power levels, high-power DC sources such as LAB/HP can be used. If energy flow in both directions is required, N35500 is suitable as a bidirectional source/sink.
BMS and cell tests
Battery cell simulators replace real battery cells. Cell voltages, SOC states, balancing, fault situations, temperature and total voltage simulations can be reproduced safely and reliably.
LAB/HP for HV components, battery pack tests and power electronics
The LAB/HP series is particularly suitable for applications that require a robust, powerful and scalable DC source. Typical areas of use include HV DC testing, DC/DC converters, battery packs, DC-link supply, inverter pre-testing, power electronics and automated test benches in development and production.
N35500 for battery, OBC DC-side and DC/DC converter tests
The N35500 series combines a powerful programmable DC source with a regenerative electronic load in one compact system. This makes it especially suitable for applications with changing energy flow, such as battery simulation, charging and discharging, DC/DC converter testing, OBC tests on the DC side and HV DC test benches with energy regeneration.
Products for automotive and e-mobility test benches
Selection of relevant product series for AC side, DC side, HV testing, BMS testing, battery simulation and powerful DC test benches.
ZGX
Bidirectional AC/DC source and regenerative load for OBC, inverter, PHIL and grid simulation tests.
N75500
Regenerative AC/DC grid simulator for AC, DC, AC+DC and DC+AC test scenarios.
N35500
Bidirectional DC source/sink for battery, DC/DC, OBC DC-side and HV testing.
LAB/HP
Programmable high-power DC source for HV components, DC/DC converters, battery pack tests, power electronics and automated test benches.
N35100
Compact bidirectional DC source for DC/DC converters, battery tests and automotive electronics.
N36200
Programmable wide-range DC source for automotive, battery, power electronics and ATE applications.
N83524
Bidirectional 24-channel battery cell simulator for BMS, active balancing and ATE test systems.
N83624
Multi-channel battery cell simulator for reproducible cell voltages, SOC states and BMS safety tests.
N9000
Modular system for cell stack, BMS HIL, fault, temperature and total voltage simulation.
Which solution fits which test task?
The table serves as an initial guide and complements the typical automotive test tasks from the NGI Automotive Electronics white paper. The final configuration is based on voltage, current, power, dynamics, interfaces, safety concept and test sequence.
| Test task | Recommended solution | Benefit |
|---|---|---|
| Charging Pile / Charging Module Testing | N75500 / N35500 / N69200 | Grid simulation on the AC side, battery or vehicle simulation on the DC side, electronic load for output characteristics, short-circuit, protection, efficiency and power factor tests. |
| OBC / BOBC Testing | ZGX / N75500 / N35500 / N69200 | Realistic AC grid conditions, V2G/regenerative operation, battery simulation, DC output testing, ripple, load dump, efficiency and protection function tests. |
| Automotive DC/DC Converter Testing | LAB/HP / N38300 / N36200 / N35100 / N69200 | HV or LV input simulation, output loading, efficiency measurement, load steps, quiescent current, overshoot, recovery time as well as OVP/UVP and short-circuit tests. |
| PDU / BDU Testing | N35500 / N69200 / DAQ | Simulation of battery pack and electrical consumers, inrush current, overload, constant current, aging and protection function tests in HV distribution and battery disconnect units. |
| Traction Battery Testing | N35500 / N35100 / NXI DAQ / NP301 | Charge/discharge cycles, capacity and aging tests, current, voltage and temperature acquisition as well as safe battery testing with a protection module against reverse connection, reverse current and arcing. |
| Motor Controller Testing | N35500 / battery simulation / regeneration | Simulation of different battery types and SOC states, testing of recuperation, energy backflow, high inrush currents and stable DC-link supply during motor start-up. |
| Automotive Electronics Testing | N36200 / N8361F / NXI Module | Supply of control units and on-board electronics, automotive waveform tests according to typical vehicle electrical system profiles, voltage dips, ramps, ground offset testing, I/O and CAN simulation. |
| Controller Test ECU / VCU / DCU | NXI I/O / NXI DAQ / CAN / relays / N36200 | Simulation and measurement of digital and analog signals, sensors, relay states, PWM, CAN communication and power supply circuits for controller and HIL-like tests. |
| Central Electrical Junction Box Testing | N36200 / N38300 / N61100 / N69200 / NXI | Testing of fuses, relays, input signals, high-side/low-side drivers, pulse current, endurance operation, load simulation, switching logic and automated evaluation. |
| Automotive BMS Testing | N9000 / N83524 / N83624 / NB201 / NXI | Cell voltage, total voltage, total current, temperature and insulation simulation, SOC validation, balancing, fault diagnosis, DC supply test and CAN/I/O communication. |
| Wiring Harness & Connector Testing | N8150A / NXI-6100 / N36200 / NXI-6501 | Momentary disconnection test, short-circuit events, current cycling, temperature rise, mechanical stress, high-speed data acquisition and report export for connector tests. |
| End-of-line & automated test systems | Customer-specific system | Combination of AC/DC source, DC load, bidirectional source/sink, battery simulator, DAQ, relays, I/O, CAN and test software for reproducible production and functional tests. |
Structured path to the suitable test solution
Send us your automotive test requirements
For an initial selection, we ideally need the most important electrical key data, the required dynamics, interfaces and planned test sequence. ET System supports you in selecting suitable AC/DC test technology and building complete test benches.