Tag: battery cycler

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’s New Program Remapping Capability Simplifies Battery Cycling

9220 Dual Bay Battery Test System - NH Research, Inc. (NHR)NH Research Inc. (NHR), a leading provider of power electronics test solutions for the automotive, aerospace and defense, energy storage and renewable energy industries, announces a new program re-mapping capability on NHR’s Enerchron® Test Management Software.

NHR’s unique program re-mapping capability enables the flexibility to use the same test program across multiple battery cyclers without having to adjust for and validate the capabilities of each cycler. This feature prevents operator error by ensuring that test programs only run on battery cyclers with the proper hardware requirements. This game-changing capability significantly reduces development time, eliminates operator error and simplifies battery test.
Enerchron® is an advanced software solution with test creation, execution and reporting tools, ideal for battery cycling evaluation. Sophisticated, dynamic test sequences are created without requiring complex programming skills. By enabling the integration of modular power stages, third-party products and control stations, NHR creates comprehensive test environments that are unique to each application.

In 2012, NHR’s Enerchron® broke the mold of traditional automated battery cycling through its unique variable-based test sequence editor and compatibility with third-party solutions and equipment. “We continue to expand the Enerchron® platform, providing increased value to our customers. Battery cycling profiles can now be easily created, run and repurposed for any Unit Under Test (UUT) or test station,” said Martin Weiss, Product Director at NH Research.

Consult with NHR’s application experts at The Battery Show 2019 and Automotive Testing Expo 2019.

The Battery Show 2019 – Booth #2027
September 10-12th, 2019 Novi, Michigan

Automotive Testing Expo 2019 – Booth #9018
October 22-24th 2019 Novi, Michigan

For more information about Enerchron®, visit:
https://nhresearch.com/software/enerchron-test-management-software

About NH Research

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 desire. For more information, visit https://www.nhresearch.com.

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