Category: EV Testing

EV Testing

Battery Test Systems for EVs

The EV industry is constantly improving technologies, through EV testing, to meet the evolving market demands for more features, lower emissions and higher performance, which are driving the development of improved battery performance, more efficient power converters and faster charging. Many EV sub-assemblies utilize NHR test equipment including: batteries, chargers, alternators, DC/DC converters, inverters, lighting control modules (LCM), and fuse boxes. For example, NHR’s test equipment is used to test EV batteries using drive-cycle simulation and emulating real-world transients. Additionally, a state of the art battery emulation mode dramatically simplifies the testing of chargers, DC/DC converters, inverters, and Vehicle to Grid (V2G) features.

NHR’s test equipment and software tools simplify testing. Our products provide engineering and manufacturing with the right tools needed to validate designs and confirm manufacturing processes by using real-world simulations. Testing performed using real-world simulations reduces cost, reduces risk, improves test coverage, and improves overall design confidence. Refer to the following page for some example solutions for Electric Vehicle sub-assembly testing.

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The Ideal Regenerative Grid Simulator for Microgrid Testing

Microgrid Solar Wind Power Testing - NH Research (NHR)

NHR’s Regenerative Grid Simulator Accurately Emulates the Utility Grid

Regenerative Grid Simulator Model 9410 - NH Research (NHR)If you’re looking for a regenerative grid simulator or grid emulator, NHR’s 9410 has key competitive advantages over the market. NHR’s Regenerative Grid simulator is ideal for simulating complex power disturbances ideal for testing micro-grid and smartgrid applications.

NHR’s Regenerative Grid Simulator (9410) is a unique four-quadrant bi-directional AC/DC source that simulates the utility voltage and regenerates power sourced by grid-tied inverters. Greater than 90% of power is returned to the facility thereby providing significant energy savings. The 9410 is used as a grid simulator, or emulator for testing PV inverters and other grid-tied products for compliance to IEEE 1547, UL 1741, and global industry standards. A wide-range of AC conditions can be emulated including phase imbalance (in voltage and/or phase angle relationship), voltage sag, frequency changes and harmonic injection.

Modular and Scalable Power

The Regenerative Grid Simulator (9410) is flexible in both output form and power level. Output can be AC or DC and the AC can be single, split or 3-phase. Frequency is programmable between 30 and 100 Hz. Power is scalable from 4 kW to 96kW. With this broad selection of power, phase configuration and frequency, this grid simulator provides the flexibility to test the widest range of grid-tied products. The included measurement system also eliminates the need for additional power meters, DMMs, oscilloscopes, or spectrum analyzers.

3 Channel Multiple Configuration - NH Research (NHR)

Figure 1 – 3 channels with multiple configuration possibilities

Accurate Emulation of Complex Power Disturbances

The Regenerative Grid Simulator (9410) is able to replicate power line disturbances through a combination of user-definable waveforms and Macros. User-defined waveforms permit generation of non-sinusoidal voltages including asymmetrical inflections, transient anomalies, voltage harmonics, or any other irregularity which can be drawn as a single-cycle. The grid simulator can emulate sub-cycle transients, phase jumps and multi-cycle line conditions as required.

Simulating Voltage Harmonics - NH Research (NHR)

Simulating Area EPS Voltage Harmonics

Simulating Sub-cycle Transients - NH Research (NHR)

Simulating Sub-cycle Transients

Simulating Phase Jump - NH Research (NHR)

Simulating Phase Jump

Simulating Abnormal Voltages - NH Research (NHR)

Simulating abnormal voltages (sags, swells & drop outs)

This modular Grid-Simulator is used to verify product AC performance while a 9200/9300 Bi-directional DC Source may be used to emulate any energy storage system.

For more information, please visit our product webpage or contact us for a quote.

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Applications Include:

  • Grid Simulation: Microgrid, Smartgrid systems
  • V2G, ESS
  • On-board Chargers, Grid-aware Chargers
  • Grid Utility Test
  • PV/Grid Tied Inverter Test
  • Compliant with UL1741, IEEE1547 and similar grid-tied standards world-wide
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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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