The power conversion section of Electric and Plug-in Hybrid vehicle (EV/PHEV) systems are composed of several power electronic units, which include the EVSE (EV Supply Equipment), on-board charger, DC/DC converter, motor driver, and more. EV/PHEV power systems are often custom-built and designed specifically for certain power electronic units. These systems are usually difficult to maintain and lack flexibility once the design is finalized, and these shortcomings will definitely impede the product development process as test methodologies evolve. The Chroma ATS (Automatic Test System) addresses the specialized requirements involved in testing power electronics during not only the development phase, but also the production phase. The benefits of our ATS are not limited to reducing manpower and prevention of human error; they also include advanced features such as automatic test data recording and creation of statistical analytical reports for design review and product improvement.
The Chroma 8000 ATS is a standard test platform that solves the conventional problem of self designed ATS’s for power electronics testing. It is built on testing technology and experience in the power electronics industry, where Chroma has been a technological leader for over 20 years. Chroma has provided over 1,500 Chroma 8000 ATS systems to customers worldwide that are being used in R&D, QA departments and production lines. Our test system is designed with an open architecture, allowing the user to easily integrate various instruments. The Chroma 8000 ATS includes a wide range of hardware choices such as AC/DC power supplies, Electronic Loads, Power analyzers, Oscilloscopes, Digital multi-meters, as well as various digital/analog I/O cards. This flexibility combined with an open architecture gives the user an adaptable, powerful and cost effective test system for the EV / HEV power electronics. The Chroma 8000 test system includes a sophisticated test executive, which includes pre-written test items. Users may also create new test items by using the Test Item Editor function. This provides the flexibility to expand your test library without limits. The Chroma 8000 ATS’s ability to satisfying the test requirements for multiple power electronic units is key to keeping consistency and reducing costs during the transition between R&D and production.
The following details for Chroma ATS illustrate applications for EV/PHEV testing. The systems not only perform the tests and report results to an isolated PC, but also network to the shop-floor (MES) system for the production line providing data logging, analysis and monitoring.
Software Platform for Chroma 8000 Systems
PowerPro III provides users with an open software architecture suited to a wide range of applications and devices. The test item editor is a powerful tool which is similar to C language, but much easier to use. It allows users to define test procedures, test condition variables, test result variables and temporary variables. The test program editor also provides a useful means to link several pre-defined test items for batch testing.
Customized ATS for EV/PHEV Maintenance Applications
The demand for charging stations is steadily growing as EV / PHEV’s gain popularity. Unlike the conventional gas station, which mainly consists of mechanical parts, the EV / PHEV charging station has Implemented sophisticated electronics for metering, controlling, and measuring the amount of energy required and transferred to the vehicle. In order to keep the charging station in optimum operating condition and maintain its accuracy, frequent service and calibration is required. Chroma has the capability to provide a customized mobile service system, which is specifically designed to perform diagnosis, measurement and meter calibration for these charging stations.
With the powertrain systems switching from internal combustion engine (ICE) mechanical designs to fully electric powertrain designs, ICE oriented auto technicians must quickly familiarize themselves with electrified systems. In order to provide optimal vehicle operating conditions, maintain serviceability and minimize the chance of a technicians exposure to electric shock hazards, the Chroma 8000 provides unique, dynamic diagnostic capabilities. These include: vehicle battery unit testing, voltage/current parameter measurement reading, CAN bus interface, diagnostic reporting, and more. The test system also provides diagnostic data through the internet directly to the vehicle manufacturer for data analysis.