Charged EVs | Kikusui’s cutting-edge energy testing options for battery, energy electronics and on-board charger functions

The worldwide electrical car trade is experiencing fast development, driving an pressing demand for energy conversion programs that aren’t solely environment friendly but additionally extremely dependable. Amongst these, the on-board charger (OBC) is a essential part, tasked with changing alternating present (AC) from varied charging infrastructures, residential, industrial, or public, into direct present (DC) appropriate for charging high-voltage battery programs.

The efficiency and security of the OBC immediately influence general car effectivity, battery well being, and consumer 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 develop into extra advanced and rigorous, notably underneath 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 hundreds allow detailed analysis, useful testing, and seamless system integration of OBCs and different essential EV energy digital elements, together with traction batteries. These instruments help sturdy characterization throughout a spread of real-world eventualities, contributing to improved design validation, compliance, and efficiency optimization in next-generation electrical mobility programs.

Electrical car OBCs function the first interface between the facility grid and a car’s high-voltage battery, enabling secure AC-to-DC conversion throughout a variety of enter circumstances. Fashionable OBCs should not solely present environment friendly unidirectional charging however more and more help bidirectional power movement for V2H/V2G features, grid-interactive providers, 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 bins into built-in items to scale back dimension, weight, and value.

These developments improve the necessity for:

• Strong AC-side resilience towards voltage sags, frequency variations, momentary interruptions, and harmonic distortion.
• Secure DC-side management, guaranteeing correct charging conduct, battery safety, and compliance with world requirements.
• Take a look at gear able to reproducing worldwide grid circumstances, enabling repeatable and accelerated growth.

Kikusui’s laboratory-grade energy programs present this managed surroundings, guaranteeing OBCs and battery programs are verified underneath real-world electrical variability with excessive constancy.

Determine 1. AC–DC Conversion of Voltage and Present Waveforms in an On-Board Charger (OBC).

AC-Facet Analysis of On-Board Chargers
The PCR-WEA/WEA2 Collection is a high-capacity AC/DC regulated energy provide designed for versatile, high-precision grid simulation. It helps all main world AC configurations used for electrical car (EV) charging, together with:

• Single-phase 120 V (generally utilized in USA)
• Single-phase 200 V three-wire (L1-N-L2, sometimes 100 V line-to-neutral, 200 V line-to-line)
• Three-phase 208V (line-to-line), widespread in industrial or industrial charging functions

A single PCR-WEA/WEA2 unit can replicate these voltage and section circumstances with out requiring extra {hardware}, considerably lowering check complexity and enabling fast configuration adjustments for world 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 incorporates a regenerative mode for diminished energy consumption and helps mix-and-match parallel operation as much as 144 kVA for scalable check programs, 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.

Accessible 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 obtainable 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-Part and Three-Part 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 diminished lab footprint.
• Distinctive Transient Dealing with for inrush and peak-load occasions.
• Superior Sequencing Capabilities to simulate disturbances, harmonics, and superior grid conduct.
• International Grid Simulation with adjustable voltage, frequency, and section.
• Confirmed Reliability, broadly utilized in Japanese automotive and client electronics industries.

Sequence Capabilities for Superior AC Simulation
The PCR-WEA/WEA2 Collection incorporates subtle waveform programming that enables engineers to duplicate advanced utility grid conduct with precision. These features are important for evaluating OBC reliability, EMC efficiency, and compliance with worldwide check 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 Part 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 situation testing.

Compliance and Requirements Testing

The collection helps testing aligned with main world 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 units earlier than formal certification, lowering growth cycles and compliance danger.

Determine 3. Numerous Sequence Capabilities: Simulation of Voltage Dips, Interruptions, and Harmonic Waveforms for Compliance with IEC 61000 Requirements

DC-Facet Analysis of On-Board Chargers
To enrich AC-side testing, Kikusui supplies highly effective DC-side check devices, together with the PXB Collection bidirectional DC energy provide and the PLZ-5WH2 Collection high-speed DC digital load.

PXB Collection – Bidirectional Excessive-Capability DC Energy Provide

The PXB Collection affords bidirectional operation, permitting each sourcing and sinking of energy for energy-regenerative testing. This reduces complete power consumption throughout prolonged check cycles.

Supporting voltages as much as 1,500 V, the PXB collection is right for evaluating high-voltage battery programs (300–750 VDC typical). Its regenerative functionality simulates each charging and discharging circumstances, intently reflecting precise EV working environments.

PLZ-5WH2 Collection – DC Digital Load

The PLZ-5WH2 Collection supplies 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 guage the OBC’s conduct underneath sudden load adjustments, guaranteeing security and reliability in real-world operation.

System Integration and Software Flexibility
By combining the PCR-WEA/WEA2, PXB, and PLZ-5WH2 programs, Kikusui delivers a completely built-in OBC check 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 underneath variable grid circumstances
• Lengthy-term endurance and effectivity testing by means of regenerative energy movement
• Harmonic, transient, and compliance testing per world requirements
• Optimized power use by means of energy regeneration

Such a setup ensures complete validation and accelerated growth of next-generation OBC and EV energy programs.

Conclusion
As EV energy electronics broaden in functionality and complexity, the necessity for high-precision, globally consultant check environments continues to develop. Kikusui’s PCR-WEA/WEA2, PXB, and PLZ-5WH2 collection present a complete answer for AC and DC analysis of OBCs, high-voltage battery programs, and associated energy electronics.

By delivering superior harmonic simulation, regenerative operation, quick transient management, and compliance-oriented sequence features, these devices allow engineers to design, validate, and combine next-generation EV charging and energy-management programs with confidence.

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