The worldwide electrical automobile trade is experiencing fast development, driving an pressing demand for energy conversion techniques that aren’t solely environment friendly but additionally extremely dependable. Amongst these, the on-board charger (OBC) is a crucial part, tasked with changing alternating present (AC) from numerous charging infrastructures, residential, business, or public, into direct present (DC) appropriate for charging high-voltage battery techniques.
The efficiency and security of the OBC instantly influence general automobile effectivity, battery well being, and person expertise. Because the EV ecosystem evolves to include superior functionalities akin to vehicle-to-grid (V2G), vehicle-to-home (V2H), and modular, distributed energy electronics, the necessities for testing and validation have turn out to be extra advanced and rigorous, notably beneath variable and dynamic electrical circumstances.
This text presents a complete overview of how Kikusui’s cutting-edge energy testing options particularly, the PCR-WEA/WEA2 collection of programmable AC/DC energy provides, the PXB collection of bidirectional DC energy provides, and the PLZ-5WH2 high-speed DC digital masses allow detailed analysis, practical testing, and seamless system integration of OBCs and different crucial EV energy digital parts, together with traction batteries. These instruments help strong characterization throughout a spread of real-world eventualities, contributing to improved design validation, compliance, and efficiency optimization in next-generation electrical mobility techniques.
Electrical automobile OBCs function the first interface between the facility grid and a automobile’s high-voltage battery, enabling protected AC-to-DC conversion throughout a variety of enter circumstances. Trendy OBCs should not solely present environment friendly unidirectional charging however more and more help bidirectional power circulate for V2H/V2G capabilities, grid-interactive companies, and power storage functions.
On the identical time, automotive producers are shifting towards compact, modular, and multifunctional energy digital assemblies, combining OBCs, DC/DC converters, and junction packing containers into built-in models to cut back measurement, weight, and value.
These developments enhance the necessity for:
- Sturdy AC-side resilience towards voltage sags, frequency variations, momentary interruptions, and harmonic distortion.
- Secure DC-side management, making certain correct charging conduct, battery safety, and compliance with international requirements.
- Check gear able to reproducing worldwide grid circumstances, enabling repeatable and accelerated improvement.
Kikusui’s laboratory-grade energy techniques present this managed surroundings, making certain OBCs and battery techniques are verified beneath real-world electrical variability with excessive constancy.
Determine 1. AC–DC Conversion of Voltage and Present Waveforms in an On-Board Charger (OBC).
AC-Aspect Analysis of On-Board Chargers
The PCR-WEA/WEA2 Sequence is a high-capacity AC/DC regulated energy provide designed for versatile, high-precision grid simulation. It helps all main international AC configurations used for electrical automobile (EV) charging, together with:
- Single-phase 120 V (generally utilized in USA)
- Single-phase 200 V three-wire (L1-N-L2, usually 100 V line-to-neutral, 200 V line-to-line)
- Three-phase 208V (line-to-line), widespread in industrial or business charging functions
A single PCR-WEA/WEA2 unit can replicate these voltage and section circumstances with out requiring extra {hardware}, considerably decreasing take a look at complexity and enabling fast configuration adjustments for international compliance testing.
The 15-model PCR-WEA2 lineup affords AC/DC output from 1 kVA to 36 kVA, with variable single- and three-phase output from 6 kVA upward. It contains a regenerative mode for lowered energy consumption and helps mix-and-match parallel operation as much as 144 kVA for scalable take a look at techniques, the collection affords:
- Output frequency flexibility as much as 5 kHz
- 4x rated peak present functionality
- 1.4x inrush present tolerance for 500 ms
These options allow engineers to precisely consider OBC efficiency throughout startup, simulate real-world grid disturbances, and validate transient dealing with throughout fast load transitions.
Obtainable energy configurations choices 1 kVA and a pair of kVA, 4 kVA, 8 kVA, 12 kVA, 16 kVA, 20 kVA, and 24 kVA. For functions requiring larger capability, parallel operation can lengthen the output as much as 96 kVA. Moreover, the three-phase PCR-WEA2 collection is out there in 3 kVA, 6 kVA, 12 kVA, 18 kVA, 24 kVA, 30 kVA, and 36 kVA fashions, with parallel growth potential as much as 144 kVA.
Determine 2. AC Energy Simulation for EV Charging: Single-Section and Three-Section 100V/200V Inputs Delivering Pure Sine Wave Outputs for 7kW, 11kW, and 22kW Charging.
Key Options and Advantages of PCR-WEA/WEA2:
- Versatile Output Configurations supporting all main EV charging voltages.
- Extremely-Compact Design offering excessive energy density for lowered lab footprint.
- Distinctive Transient Dealing with for inrush and peak-load occasions.
- Superior Sequencing Features to simulate disturbances, harmonics, and superior grid conduct.
- World Grid Simulation with adjustable voltage, frequency, and section.
- Confirmed Reliability, extensively utilized in Japanese automotive and client electronics industries.
Sequence Features for Superior AC Simulation
The PCR-WEA/WEA2 Sequence incorporates subtle waveform programming that enables engineers to copy advanced utility grid conduct with precision. These capabilities are important for evaluating OBC reliability, EMC efficiency, and compliance with worldwide take a look at requirements.
Simulation of Energy Disturbances
The system can reproduce a spread of real-world anomalies, together with:
- Undervoltage/Overvoltage
- Voltage dips, swells, and fluctuations
- Instantaneous interruptions
- Waveform distortion
These simulations assist confirm OBC operation throughout brownouts, unstable infrastructure, and transient grid occasions.
Harmonic and Section Management
The PCR-WEA/WEA2 helps harmonic synthesis as much as the fortieth order, enabling detailed evaluation of energy issue correction (PFC) conduct and OBC EMI efficiency. Adjustable preliminary section settings (e.g., 0°, 90°, 270°) allow worst-case startup state of affairs testing.
Compliance and Requirements Testing
The collection helps testing aligned with main international energy high quality requirements, akin to:
- IEC 61000-4-11 – Voltage dips, quick interruptions, variations
- IEC 61000-4-28 – Frequency variations
- IEC 61000-4-34 – Voltage disturbances for high-current gear
These options assist producers validate gadgets earlier than formal certification, decreasing improvement cycles and compliance danger.
Determine 3. Varied Sequence Features: Simulation of Voltage Dips, Interruptions, and Harmonic Waveforms for Compliance with IEC 61000 Requirements
DC-Aspect Analysis of On-Board Chargers
To enrich AC-side testing, Kikusui offers highly effective DC-side take a look at devices, together with the PXB Sequence bidirectional DC energy provide and the PLZ-5WH2 Sequence high-speed DC digital load.
PXB Sequence – Bidirectional Excessive-Capability DC Energy Provide
The PXB Sequence affords bidirectional operation, permitting each sourcing and sinking of energy for energy-regenerative testing. This reduces complete power consumption throughout prolonged take a look at cycles.
Supporting voltages as much as 1,500 V, the PXB collection is good for evaluating high-voltage battery techniques (300–750 VDC typical). Its regenerative functionality simulates each charging and discharging circumstances, intently reflecting precise EV working environments.
PLZ-5WH2 Sequence – DC Digital Load
The PLZ-5WH2 Sequence offers high-speed transient response and exact dynamic load management, enabling correct measurement of OBC output traits akin to voltage regulation, ripple, and transient response.
With voltage dealing with as much as 1,000 V, it permits engineers to judge the OBC’s conduct beneath sudden load adjustments, making certain security and reliability in real-world operation.
System Integration and Utility Flexibility
By combining the PCR-WEA/WEA2, PXB, and PLZ-5WH2 techniques, Kikusui delivers a totally built-in OBC take a look at surroundings able to simulating each grid-side and battery-side circumstances with precision.
This built-in platform permits:
- Finish-to-Finish AC–DC efficiency testing beneath variable grid circumstances
- Lengthy-term endurance and effectivity testing by regenerative energy circulate
- Harmonic, transient, and compliance testing per international requirements
- Optimized power use by energy regeneration
Such a setup ensures complete validation and accelerated improvement of next-generation OBC and EV energy techniques.
Conclusion
As EV energy electronics broaden in functionality and complexity, the necessity for high-precision, globally consultant take a look at environments continues to develop. Kikusui’s PCR-WEA/WEA2, PXB, and PLZ-5WH2 collection present a complete resolution for AC and DC analysis of OBCs, high-voltage battery techniques, and associated energy electronics.
By delivering superior harmonic simulation, regenerative operation, quick transient management, and compliance-oriented sequence capabilities, these devices allow engineers to design, validate, and combine next-generation EV charging and energy-management techniques with confidence.
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