Category: EV Powertrain Testing

Electric Vehicle Market Drivers & Testing Requirements

Electric Vehicle Transportation - NH Research (NHR)

EV Batteries & Powertrains Increase in Power Levels

As the electric vehicle (EV) industry continues to accelerate, automotive engineers must address new testing challenges for designing higher performance batteries, electric powertrain systems, power electronic components and DC fast chargers. Power levels are increasing across e-mobility markets such as passenger electric vehicles, heavy duty electric trucks, and electric fleets. These market trends require test solutions that can test today’s technologies and tomorrow’s innovations.

Power and voltage levels are transitioning from a traditional 300/400VDC level toward 800/1000VDC. Higher voltages permit faster charging and increase power transfer while reducing vehicle weight. For example, in 2019 most available BEVs were similar to Tesla’s Model 3 and GM’s Chevy Bolt, with a nominal voltage of ~350VDC, whereas Porsche announced the Taycan architecture utilizing a higher 800VDC battery system. This higher voltage allows nearly three times (3x) the additional power to be transferred for the same wire size. Porsche demonstrated this with an IONITY system charging at 350kW, which is nearly 3x the 120kW available through other “fast” supercharging networks.

It is expected that both 800V and 350V vehicles will charge at an electric-only refueling station the same way gasoline and diesel cars do today. Engineers should keep this dual-voltage reality in mind when specifying the power requirements because many of the high-power test systems are only designed for a single range. Selecting a system that can provide both traditional and high-voltage levels ensures that the right equipment is available to meet current and future needs. It is equally important that a battery emulation system reacts with a quick voltage response to changes in current or power draw in order to accurately simulate the electrical storage system (battery).

Auto manufacturers have dramatically increased the relative capacity of the battery packs in their vehicles to reduce “range anxiety”. For example, the 2019 Nissan Leaf has a 50% larger battery compared to older 40kW models, and Tesla’s Model S offers a 100kW battery, that is 66% larger than the original standard-sized battery. Battery capacity and battery performance are always improving, suggesting that engineers must consider flexibility and programmability in selecting a battery test or battery emulation solution.

EV Testing Requires Modular, Scalable Test Solutions

NHR Provides Modular, High Voltage Bi-Directional Power up to 2.4 MW

NHR’s ev test equipment is designed for fully independent operation and can be paralleled, increasing the maximum power and current capability to the level required. This modular expansion through paralleling ensures that you can start testing to today’s application levels, knowing that additional power is available if needed in the future. Higher-power models provide dual ranges, allowing the equipment to test and emulate today’s batteries and provide the right tool that can scale to address increases in battery voltage and power.

The 9300 High Voltage Battery Test System has a dual power range that covers both lower (up to 600 V) and higher power (up to 1200 V) applications using a single product. This modular system can be scaled up to 2.4 MW in 100 kW building blocks, offering a wide operating envelope. With NHR’s battery emulation mode, customers are able to simulate a wide range of battery power levels without having to change test equipment. Alternatively, the 9200 Battery Test System has a multi-channel capability with the possibility to mix and match voltage and current levels at lower power ranges. This battery cycler and battery emulator is expandable in 12kW block sizes and has voltage options from 40V to 600VDC. This series uses the same drivers, touch panel controls, and software options, making NHR your ideal solution partner for both high-power and low-power EV architectures.

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NHR Presents Live Webinar: Electric Powertrain Next Gen Test Solutions, on May 13th

EV X-ray Powertrain Side - NH Research (NHR)

NH Research Inc., a leading provider of power electronics and battery test solutions for the automotive, industrial, energy storage, and critical-power markets, will be hosting a free live webinar on Electric Powertrain Next Gen Test Solutions on May 13th, 2020.

In this live webinar, Ben Jackson, Senior Applications Engineer at NHR, will discuss key industry trends impacting electric powertrain developments, current challenges and opportunities, and key factors in selecting the right test approach. This session will cover modern electric powertrain test solutions and key considerations for battery emulation.

Webinar Description:
As electrification continues to accelerate in automotive and aerospace, engineers must address new testing challenges for hybrid and electric powertrain. Modern propulsion system architectures are fundamentally different and present new challenges and risks. Therefore, it is important for engineers to use the most effective technologies and test approaches to ensure product performance, safety, reliability and reduced time to market.

Electric powertrain systems are complex and raise new testing challenges including increased voltage and power levels, long test times, and different safety risks. Traditional powertrain test approaches rely on unidirectional devices that have drawbacks and limitations. Next generation battery emulation provides a bi-directional approach that sinks and sources to maintain voltage regulation, accepts back EMF which prevents safety hazards, and has isolated input and output paths to eliminate single points of failure.

This session will review how modern solutions for emulating batteries are the right approach for faster, scalable and more repeatable testing of electric powertrain systems. As electrification is evolving to higher power demands, the ability to emulate a battery with speed and precision is critical. Battery emulation can substantially reduce test time, risk, energy consumption and operating costs.

In this webinar, learn about:

  • Key Industry Trends, Challenges & Opportunities
  • Electric Powertrain Test Solutions
  • Battery Emulation Differentiators – What to Look for in a Battery Emulator
  • Cohesive, Scalable, Intuitive Software Solutions

If you cannot attend the live event, please register and we will send you the recording.

  • Webinar Event: Electric Powertrain Next Generation Test Solutions
  • Dates: Wednesday, May 13, 2020 at 2-3pm EDT
  • Register now

For more information on our EV Powertrain Solutions, visit our application page.

About NH Research

NHR enables electrification by accelerating innovation, validation and functional testing of today’s technologies. Backed by over 50 years of experience in power conversion and power electronics test systems and instruments, our test solutions deliver the performance, simplicity, and safety that engineers and researchers in aerospace, defense, automotive and energy industries require.

For more information, visit www.nhresearch.com.

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NHR Presents & Exhibits at APEC 2020 in New Orleans, Louisiana

Battery Test Systems & Grid Simulator - NH Research, Inc. (NHR)NH Research Inc., a leading provider of power testing instruments and systems for the automotive, industrial, energy storage, and critical-power markets, will be presenting at APEC 2020.

Martin Weiss, Product Director at NHR, will present in an industry session entitled, “Using Battery & Fuel Cell Emulation for testing EV batteries, DC fast chargers & Powertrains”. In this session, he’ll discuss new technology trends in battery and fuel cell emulation, and key factors in selecting the right test solution. This session will  cover how technologies are used today in R&D and production for DC Fast Chargers, Powertrain, and other EV applications.

NHR will also be presenting at the Exhibitor Seminar on APEC’s opening day. We’ll be showcasing industry leading test solutions including our Battery Module/Pack Testers, Battery Emulation Systems, Grid-Simulators, and AC Loads. Visit booth # 1717 to learn about NHR’s flexible and expandable test solutions for advanced battery technologies, electric and hybrid vehicles, and critical power technologies. Application engineers will be on-hand to demonstrate NHR’s flexible 9200 & 9300 series battery module and pack test systems, 9410 regenerative grid simulator, and 9430 4-Quadrant AC loads.

Event: APEC 2020
Location: New Orleans, Louisiana
Dates: March 15 – 19, 2020
Visit Booth: #1717

NHR Exhibitor Seminar: Battery Emulation Test Solutions: Technology Trends & Opportunities
Date: Tuesday, March 17
Time: 2:30 PM – 3:00 PM
Location: Exhibit Theater 3

NHR Industry Presentation: Using Battery & Fuel Cell Emulation for Testing EV Batteries, DC Fast Chargers & Powertrains
Date: Thursday, March 19
Time: 2:35 PM – 3:00 PM
Location: R01

For more information on our Battery Test Solutions or our EV Powertrain Testing Solutions, visit our application page.

About NH Research

NH Research, Inc. (NHR) enables electrification by accelerating innovation, validation and functional test of today’s technologies. Backed by over 50 years of experience in power conversion and power supply test systems we provide world class test instruments and systems. Our solutions provide the performance, simplicity, and safety that engineers and researchers desire.

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