Electric vehicle high voltage performance

The high voltage piezoelectric performance test system for electric vehicles is suitable for the high voltage parts test of new energy vehicles in the voltage class DC 60 V ~ 1500 V. HV battery systems, DC/DC converter HV/LV.

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Description

The high voltage piezoelectric performance test system for electric vehicles is suitable for the high voltage parts test of new energy vehicles in the voltage class DC 60 V ~ 1500 V. HV battery systems, DC/DC converter HV/LV, On-board chargers and Air conditioning compressors can be verified through a series of electrical characteristic tests Electrical parameters and safety of high voltage components such as conditioning compressor. From EVTS 150 c30 electric performance of high voltage measuring support DC 0 V to 1500 V voltage output, voltage slope control more than 250 V/ms, to complete the ISO 21498-2-2021 test project, At the same time, it can meet the relevant test requirements of LV 123 and VW 80300_2021, and the system has strong scalability.

Features：

  • Voltage slope control greater than 250 V/ms;
  • Meet the latest ISO 21498-2:21st, VW 80300:2021-02 standard test projects;
  • Simulate the complex electrical environment of high voltage components of new energy vehicles in the actual scene;
  • Test the scheduling function;
  • Support DC 0 V ~ 1500 V voltage output, can be arbitrarily edited waveform output, two-way power supply;
  • The system has strong scalability, and the power supply can be extended to 1 main N slave, so that the output current can achieve 60 A, 120 A, 240 A…

Standard

  • ISO 21498-2-2021
  • LV 123, 2009-11
  • VW 80300:2021-02
  • MBN 11123 2019-10

Specifications

 

System Equipment Composition
Number Name Model Introduction
1 High voltage integrated performance tester for electric vehicles EVTS 150C30

Output voltage: 0 ~ 1500 Vdc; Current: 240 A; Power: 120 kW (single power module 30 kW / 60 A);

Power/current extension: 1 N from the Lord;

Note: according to the actual power/current need to choose power supply module in parallel;
2 Dc decoupling capacitor C150C10 >10mF, maximum input voltage 1500 Vdc; Current: 100 A
3 High voltage manual network AN 150C30

Impedance: 10 mΩ, 25 mΩ, 50 mΩ, 100 mΩ ;Built-in capacitance ≥10 mF;

Maximum input voltage: 1500 Vdc; Current: 300 A;

AN 1501 n: 100 A / 1500 Vdc, built-in capacitance of 10 or higher mF;

Applicable to the ISO 21498-2-2021 and MBN_11123 standards;
4 High voltage test set HTS 150C30

Impedance: 50 mΩ, 100 mΩ, 200 mΩ; Capacitance 10 mF;

Maximum input voltage: 1500 Vdc; Current: 300 A;

HTS 1501:100 A / 1500 Vdc, built-in capacitance 10 mF;

Apply to VW 800300:2021-02 standards;
5 Ripple signal generator RSG 80C50

10 Hz ~ 300 kHz; Power: 5000 W;

Note: according to the actual power/current demand to choose corresponding generator model;

RSG 40C20: power 800 W;

RSG 80C100: power 10 KW;
6 coupling transformer TPT-7637-4C100B1、B2

10Hz ~ 300 kHz ;Current: 300 A;

Note: Select the corresponding generator model according to the actual current demand;

TPT-7637-4C100B:100 A /10 Hz ~ 300 kHz

TPT-7637-4C1000C:1000 A /300 Hz ~ 300 kHz
7 Electric vehicle dumping load simulator EVDG 20

VW80300-2021 ：EHV-10-1 / EHV-10-2;

Pulse amplitude: 20 V ~ 200 V;

DUT load capacity: 1000 Vdc / 100 A;
8 High-voltage pulse jamming generator for electric vehicles EVPG 20

VW80300-2021 ：EHV-16

Pulse amplitude: 20 V ~ 200 V;

DUT bearing capacity: 1000 Vdc / 100 A.
9 Automotive immunity test software Autolab Automotive immunity test software
10 oscilloscope MDO32 Bandwidth 1GHz, sampling rate 5 G Sa/s, 2 analog channels
11 High voltage differential voltage probe THDP0200

Attenuation:50 X / 500 X，bandwidth:200 MHz；

Maximum voltage 1500 Vdc；
12 current probe PT-722 DC ~ 200 kHz，0.5 ~ 1000 A (4000 Ap – p)
ISO 21498-2 Match the situation
Test requirement Type of test Match the situation Equipment needed
6.2 The voltage varies within the working range Immunity – voltage variation satisfy

1. Oscilloscope

2. Current probe

3. Automotive immunity test software

4. High voltage differential voltage probe

5. High voltage manual network

6. Ripple signal generator

7. High voltage integrated performance tester for electric vehicles

8. Coupling transformer
6.3 Generated voltage slope Emission satisfy
6.4 Voltage slope immunity Immunity – voltage variation satisfy
6.5 Generated voltage ripple Emission satisfy
6.6 Voltage Ripple immunity Immunity – DC ripple satisfy
6.7 Overvoltage Immunity – voltage variation satisfy
6.8 Undervoltage Immunity – voltage variation satisfy
6.9 Voltage Offset Immunity – voltage variation satisfy
6.10 The resulting throw load Emission satisfy
6.11 Throw load voltage immunity Immunity – voltage variation satisfy
Note: The test was carried out by the automotive immunity test software.
LV 123 Match the situation
Test requirement Type of test Match the situation Equipment needed
10.4.1 Unlimited operating capability range Immunity – voltage variation satisfy

1. Oscilloscope

2. Current probe

3. Automotive immunity test software

4. High voltage differential voltage probe

5. High voltage manual network

6. Ripple signal generator

7. High voltage integrated performance tester for electric vehicles

8. Coupling transformer
10.4.2 Upper limit of operation capability Immunity – voltage variation satisfy
10.4.3 Lower limit operating capability range Immunity – voltage variation satisfy
10.4.4 Limit operating capacity range Immunity – voltage variation satisfy
10.4.5 Dynamic voltage – immunity Immunity – voltage slope change satisfy
10.4.6 Voltage ripple emission Immunity – DC ripple satisfy
10.4.7 Overvoltage Immunity – voltage variation satisfy
10.4.8 Undervoltage Immunity – voltage variation satisfy
10.4.9 Throw load Immunity – voltage variation satisfy
10.4.10 Voltage excursion Immunity – voltage variation satisfy
10.4.11 The interaction between low-and-high pressure systems Functional test Power supply only
Note: LV 123 standard against ISO 21498-2-2021 standard requirements.
VW80300_2021 Match the situation
Test requirement Type of test Match the situation Equipment needed
EHV-01 The voltage varies within the operating range Immunity – voltage variation satisfy

1. Oscilloscope

2. Current probe

3. Automotive immunity test software

4. High voltage differential voltage probe

5. High voltage test set

6. Ripple signal generator

7. High voltage integrated performance tester for electric vehicles

8. Coupling transformer

9. Electric vehicle dumping load simulator

10.High-voltage pulse jamming generator for electric vehicles
EHV-02 Operate within the overvoltage range Immunity – voltage variation satisfy
EHV-03 Operate in the undervoltage range Immunity – voltage variation satisfy
EHV-04 Pre-charge Functional test No satisfy
EHV-05 High voltage generated Emission satisfy
EHV-06 The system high voltage fluctuates Immunity – voltage variation satisfy
EHV-07 Energy storage device high voltage dynamic Battery testing No satisfy
EHV-08 High voltage ripple generated Emission satisfy
EHV-09 System high voltage ripple Immunity – DC superimposed ripple satisfy
EHV-10 Throw load Immunity – Pulse immunity satisfy
EHV-11 High voltage offset Immunity – pulse variation satisfy
EHV-12 High voltage overcurrent Current variation Power supply only
EHV-13 High pressure life Periodic test Power supply only
EHV-14 High voltage component switch durability test Periodic test Power supply only
EHV-15 High voltage interlock service disconnects and crash signal operation Functional test Power supply only
EHV-16 High voltage pulse Immunity – Pulse immunity satisfy

Note:

1. The VW 80300 _2021 artificial network (HTS 150 c30) and ISO 21498-2-2021 standard in different network.

2. The EHV – 04 early charging: working parts in the process of the charging function when the function state of confirmation.

3. The EHV – 07 energy storage device of high voltage dynamic, by changing the load current mutation.

4. The EHV – 12 high pressure flow, by changing the DUT output load current increase 3 times.

5. EHV – 13 high service life, programmable ac/dc power frequency to 40 KHz.

6. EHV – 14 high-pressure components switch durability test, reliability test.

EVTS 150C30
High voltage integrated performance tester for electric vehicles-technical parameters
Equipment model EVTS 150C30 (Legend) EVTS 150C10
Line Voltage Max 1500 VDC 1500 VDC
Max Current 240 A 120 A
Max power 120 W 60 W
Number of power modules 4 sets (single 30KW / 60A) 2 sets (single 30KW / 60A)
Overvoltage protection range 0 ~ 1650 V 0 ~ 1650 V
Overcurrent protection range 0 ~ 264 A 0 ~ 132 A
Voltage range 0 ~ 1500 V
Waveform Sine waves, triangular waves, slope waves
Amplitude and position change Static, linear
Maximum number of supported segments 100
Input/output port 100A solid port, 300A high voltage shielding terminal 100A solid terminal
Extend Current and power can be customized expansion, parallel power modules, 1 master N slave.
Generate throw load voltage function
Dimensions 35 U 22 U
Weight 305 kg (with power supply) 220 kg (with power supply)

Note: the power 1 3 from the Lord, the output maximum 240 A, adapter 00 A test system (single power supply 30 kw / 60 A)

power supply 1 1 from the Lord, the output maximum 120 A, adaptation 100 A test system (single power 30 kw / 60 A) need more current & power output expansion power supply module number, please.

C150C10
Dc decoupling capacitor-technical parameters
Input maximum DC voltage 1500 V 100A
Capacity ＞10 mF
Operating power supply range AC 110 V / 220 V ±10 %，50 Hz ~ 60 Hz
Input/output port 100A solid terminal
Fuse 6 A
Max Power Dissipation 100 W
Dimensions 22 U
Weight Approx. 70 kg
Note: This capacitor is integrated into the HTS 1501 and AN 1501N, and if you review one of these two devices, you do not need to review this device again.

AN 150C30
High voltage manual network-technical parameters
Unit type AN 150C30 (Legend) AN 1501N
Test voltage Vmax 1500 V DC 1500 V DC
Impedance 0 mΩ、10mΩ、25 mΩ、50 mΩ、100 mΩ impedance curve 0 mΩ、10mΩ、25 mΩ、100 mΩimpedance curve
Inductance 1 μH 1 μH
Decoupling capacitor ≥10 mF ≥10 mF
Grounded capacitance 1 μF 1 μF
Frequency range 10 Hz ~ 150 kHz 10 Hz ~ 150 kHz
Capacitance voltage monitoring Lower computer screen display Nixie display
Input/output port 16A banana head terminal, 300A high voltage shielding terminal 16A banana terminal, 100A solid terminal
Temperature protection

The device stops running when the internal temperature exceeds

80 ° C
Max Power Dissipation 350 W 250 W
Dimensions 35 U 22 U
Weight 230 kg 178 kg
Note: The manual network complies with 3 impedances required by ISO 21498-2-2021 and 1 impedance required by MBN_11123 for 300 A test systems. The manual network meets the three impedances required by ISO 21498-2-2021 and is suitable for 100 A test systems.

HTS 150C30
High voltage test set-technical parameters
Unit type HTS 150C30 (Legend) HTS 1501
Test voltage Vmax 1500 V DC 1500 V DC
Test current Imax 300 A 100 A
Impedance Impedance curves of 0 mΩ, 50 mΩ, 100 mΩ, 200 mΩ
decoupling capacitor 10 mF（±10 %） 10 mF（±10 %）
Box inductance 2*1 uH（±10 %） 2*1 uH（±10 %）
Cy 220 nF（±10%）
Capacitance voltage monitoring Lower computer screen display Nixie display
Input/output port 16A banana terminal, 300A high voltage shielding terminal /16A banana terminal, 100A solid terminal, 300A high voltage shielding terminal 16A banana terminal, 100A solid terminal /100A solid terminal
Temperature protection The device stops running when the internal temperature exceeds 80 ° C
Frequency range 10 Hz ~ 150 kHz 10 Hz ~ 150 kHz
Max Power Dissipation 350 W 500 W
Dimensions 35 U 22 U
Weight 275 kg 75 kg
Note: The manual network meets the 3 impediances required by VW 80300_2021 standard and is suitable for 100A and 300A test systems.

TPT-7637-4C300B1、B2
Coupling transformer-technical parameters
Unit type TPT-7637-4C300B1, B2 (Legend) TPT-7637-4C100B TPT-7637-4C1000C TPT-7637-4C1000B
Maximum unsaturated voltage (Vpp) 140 Vpp 140 Vpp 160 Vpp（1:1） 160 Vpp（2:1）
Maximum coupling current (App) 100 App 100 App 240 App（4:1） 400 App（4:1）
Maximum EUT current (A) DC 300 A DC 100 A DC 1000 A DC 1000 A
Maximum EUT voltage (V) DC 1000 V
Input/output port 16A banana terminal /300A high voltage shielding terminal 100A solid terminal, through the core terminal
Turns ratio

1：11：1

2：1

4：1

2：1

4：1
Frequency range 10 Hz ~ 300 kHz 300 Hz ~ 150 kHz
Dimensions 440 mm (L)*190 mm (H)*585 mm (D) 800 mm(L)* 1150 mm(H)*1405 mm(D)
Weight Single unit 65 kg 60 kg 570 kg
Up to 300 A secondary current for 300 A test systems. Maximum 100 A secondary current for 100 A test systems.

600 A DC/1000 V DC @Max 20 min;

1000 A DC/1000 V DC @Max 10 min

RSG 80C50
Ripple signal generator-technical parameters
Unit type RSG 80C50 (Legend) RSG 40C20
Up to standard ISO/TS 7637-4: 2020、 ISO 21498: 2021、 VW 80300: 2021
Frequency range 10Hz ~ 300kHz
Stepped frequency 0.01Hz
Open-circuit output voltage 140 Vpp 80 Vpp
Ripple dwell time 2 s ~999 s, resolution 0.1s 1 s ~10 s, resolution 0.1s
Generator overcurrent protects peak current 50 A 20 A
Input/output port 100A solid terminal
Max Power Dissipation 5000 W 800 W
Dimensions 22 U 4 U
Weight Approx. 156 kg Approx. 25 kg
Note: This ripple signal generator has A maximum power of 5000 W and is suitable for test systems below 300 A. This ripple signal generator has A maximum power of 800 W and is suitable for test systems up to 100 A.

EVDG 20
Electric vehicle dumping load simulator-technical parameters
VW 80300_2021 (EHV-10) EHV-10-1 EHV-10-2
Pulse waveform feature Approximate double exponential wave
Pulse voltage amplitude 20V ~ 200V，±10%
Calibration voltage 50V ~ 200V，±10% 20V ~ 200V，±10%
Pulse width 10ms（0-0%）±10%@2ΩLoad ≥1ms (0-0%), open circuit
Voltage change rate (0%-100%) ≥250V/ms ≥3000V/ms
Input/output port 100A solid terminal
Nominal output impedance 0.16 Ω
Pulse interval time 3-99s
Pulse polarity Positive only
Pulse number 1-99
Pulse triggering mode Manual, automatic, external
Pulse coupling mode Pulse coupled transformer
DUT capacity DC 1000V/100A (customizable)
Dimensions 22U
Weight Approx. 187 kg
Note: Load capacity up to 100 A, larger current systems need to be customized.

VPG 20
High-voltage pulse jamming generator for electric vehicles-technical parameters
VW 80300_2021 (EHV-16) Test case 1 Test case 2
Pulse waveform feature Approximate square wave
Pulse voltage amplitude 20V ~ 200V，±10%
Calibration voltage 75V ~ 200V，±10%
Pulse width 1μs ~ 20μs，±10% 1μs ~ 5μs，±10%
Voltage change rate (0%-100%) ＞1V/ns
Input/output port 16A banana terminal, 100A solid terminal /100A solid terminal
Nominal output impedance 0.16Ω
Pulse polarity Positive, negative, first positive and then negative
Pulse number 1 ~ 100
Pulse interval time 0.1 ~ 99 s
Number of test groups 1 ~ 100
Test group spacing 1 ~ 10 s
Pulse triggering mode Manual, automatic, external
Pulse coupling mode Coupling capacitance 100μF/ line
DUT capacity DC 1000V/100A (customizable)
Dimensions 6U
Weight Approx. 69 kg
Note: Load capacity up to 100 A, larger current systems need to be customized.
Suggested selection table
Name/ Model

100A

high voltage performance system

300A

high voltage performance system
High voltage integrated performance tester for electric vehicles EVTS 150C10 √  
EVTS 150C30   √
High voltage manual network AN 1501N √  
AN 150C30   √
High voltage test set HTS 1501 √  
HTS 150C30   √
Dc decoupling capacitor C150C10 √  
Ripple signal generator RSG 40C20 √  
RSG 80C50   √
Coupling transformer TPT-7637-4C100B √  
TPT-7637-4C300B1/B2   √
TPT-7637-4C1000B    
TPT-7637-4C1000C    
Electric vehicle dumping load simulator EVDG
20		 √  
High-voltage pulse jamming generator for electric vehicles EVPG 20 √  
Note: EVDG, EVPG equipment maximum 100A, if larger load current needs to be customized.

 

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Electric vehicle high voltage performance test system Datasheet

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