Test equipment for OBCs, 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 testing with grid and battery simulation
Realistic electrical conditions for development, validation and production
Electrified vehicles place high demands on test equipment. In addition to voltage and current, dynamic response, energy recovery, safety, interfaces and repeatable test sequences are essential.
From individual instruments to complete test benches
ET System supports the selection of suitable AC/DC test equipment and the integration of complete test systems. Depending on the application, AC/DC power supplies such as N78300, 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 OBCs, DC/DC converters, BMS, inverters and HV components
Typical applications include on-board charger testing, DC/DC converter testing, BMS HIL testing, battery pack testing, charging infrastructure, inverter validation, endurance testing, burn-in and automated end-of-line testing.
Test setups for OBCs, DC/DC converters, BMS and HV components
The following test applications represent typical requirements in automotive and e-mobility projects.
On-board charger testing
The AC input is supplied by a programmable AC/DC power supply such as N78300 or a regenerative grid simulator. On the DC side, a bidirectional DC source/sink or electronic load simulates the vehicle battery. This enables testing of charging profiles, grid influences, efficiency, protection functions and operating limits.
DC/DC converter testing
The input and output are supplied or loaded under controlled conditions. High-power DC sources such as LAB/HP can be used for higher voltages and power levels. Where power flow in both directions is required, N35500 provides a bidirectional source/sink solution.
BMS and cell testing
Battery cell simulators replace physical battery cells. Cell voltages, SOC states, balancing, fault conditions, temperature and total voltage can be simulated safely and repeatably.
LAB/HP for HV components, battery pack testing and power electronics
The LAB/HP series is particularly suitable for applications requiring a robust, powerful and scalable DC source. Typical uses include HV DC testing, DC/DC converters, battery packs, DC-link supply, preliminary inverter testing, power electronics and automated test benches in development and production.
N35500 for battery, OBC DC-side and DC/DC converter testing
The N35500 series combines a powerful programmable DC source with a regenerative electronic load in a compact system. This makes it particularly suitable for applications with changing power flow, including battery simulation, charging and discharging, DC/DC converter testing, OBC testing on the DC side and HV DC test benches with energy recovery.
Products for automotive and e-mobility test benches
Selected product series for AC-side and DC-side testing, HV testing, BMS testing, battery simulation and high-power DC test benches.
ZGX
Bidirectional AC/DC source and regenerative load for OBC, inverter, PHIL and grid simulation testing.
N75500
Regenerative AC/DC grid simulator for AC, DC, AC+DC and DC+AC test scenarios.
N78300
Programmable AC/DC power supply for single-phase and three-phase AC input testing of OBCs and charging modules. Frequency variation from 1–500 Hz and harmonics up to the 50th order at a 50/60 Hz fundamental frequency.
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 testing, power electronics and automated test benches.
N35100
Compact bidirectional DC source for DC/DC converters, battery testing 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 systems.
N83624
Multi-channel battery cell simulator for repeatable cell voltages, SOC states and BMS safety testing.
N9000
Modular system for cell stack, BMS HIL, fault, temperature and total voltage simulation.
Which solution fits your test application?
This table provides initial guidance and complements the typical automotive test applications described in the NGI Automotive Electronics White Paper. Detailed system selection is based on voltage, current, power, dynamic response, interfaces, safety requirements and test sequences.
| Test application | Recommended solution | Benefits |
|---|---|---|
| AC input and harmonic testing | N78300 | Single-phase and three-phase AC supply, 1–500 Hz, harmonics up to the 50th order at a 50/60 Hz fundamental frequency and programmable R/L output impedance for OBC and charging module input testing. Up to 25 kVA in AC mode at 20–500 Hz; the 25 kVA model provides up to 21 kVA at 1–19.99 Hz. Available power depends on the model and output configuration. |
| Charging station / Charging module testing | N78300 / N75500 / N35500 / N69200 | Programmable AC supply with N78300 or regenerative grid simulation with N75500; battery or vehicle simulation on the DC side, and an electronic load for output characteristics, short-circuit, protection, efficiency and power factor tests. |
| OBC / BOBC testing | N78300 / ZGX / N75500 / N35500 / N69200 | AC input testing with N78300; ZGX or N75500 for V2G/regenerative operation on the AC side. 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, OVP/UVP and short-circuit testing. |
| PDU / BDU testing | N35500 / N69200 / DAQ | Simulation of battery packs and electrical loads, inrush current, overload, constant-current, ageing and protection function tests for HV distribution and battery disconnect units. |
| Traction battery testing | N35500 / N35100 / NXI DAQ / NP301 | Charge/discharge cycles, capacity and ageing tests, current, voltage and temperature acquisition, and safe battery testing with a protection module against incorrect connection, reverse current and arcing. |
| Motor controller testing | N35500 / Battery simulation / Regeneration | Simulation of different battery types and SOC states, testing of regenerative braking, reverse power flow, high inrush currents and stable DC-link supply during motor start-up. |
| Automotive electronics testing | N36200 / N8361F / NXI modules | Powering control units and on-board electronics, automotive waveform testing with typical vehicle electrical system profiles, voltage dips, ramps, ground offset testing, I/O and CAN simulation. |
| ECU / VCU / DCU controller testing | NXI I/O / NXI DAQ / CAN / Relays / N36200 | Simulation and measurement of digital and analogue signals, sensors, relay states, PWM, CAN communication and supply circuits for control unit testing and HIL-related applications. |
| Central electrical junction box testing | N36200 / N38300 / N61100 / N69200 / NXI | Testing of fuses, relays, input signals, high-side/low-side drivers, pulse current, endurance, 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 testing and CAN/I/O communication. |
| Wiring harness & connector testing | N8150A / NXI-6100 / N36200 / NXI-6501 | Momentary disconnection testing, short-circuit events, current cycling, temperature rise, mechanical stress, high-speed data acquisition and report export for connector testing. |
| End-of-line & automated test systems | Custom system | A combination of AC/DC source, DC load, bidirectional source/sink, battery simulator, DAQ, relays, I/O, CAN and test software for repeatable production and functional testing. |
A structured approach to the right test solution
Send us your automotive test requirements
For an initial selection, please provide the key electrical specifications, required dynamic response, interfaces and planned test sequences. ET System supports you in selecting suitable AC/DC test equipment and building complete test benches.