EV Automotive and Battery Test Advancements

As the automotive industry advances power conversion and battery technologies, Chroma has been actively working to improve electric vehicle (EV) testing performance and cost by developing flexible power conversion test equipment, regenerative battery test systems, electrical safety testers, and motor and wound component testers.

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EV Power Conversion Testing

The power conversion within an electric vehicle (EV) is composed of several power electronic units, which include the AC or DC EVSE (EV Supply Equipment), on-board charger, DC-DC converter, and motor driver. Chroma’s EV automated test equipment addresses the specialized requirements involved in testing the power electronics of electric vehicles during design validation as well as production. The benefits of our automated test systems include flexibility, speed, and test data recording as well as providing statistical analytical reports for design review and product improvement.


AUTOMATED TEST SOLUTIONS

Automated test - EV on board charger OBC

EV On-Board Charger / DC-DC Converter
Electric Vehicle Automated Test System

Test: On-board chargers, DC-DC converter

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Automated test - EV control unit

EV Control Unit / DC-DC Converter
Electric Vehicle Automated Test System

Test: Controllers, DC-DC converter

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Automated test - EV Charging equipment SAE-J1772

EV Charging Equipment (EVSE)
Electric Vehicle Automated Test System

Test: UL approved SAE J1772 EVSE Communication Protocol Automated Test System

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DC POWER SUPPLIES

Programmable Benchtop DC Power
Up to 150W

Test: Low voltage DC accessories on board

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Programmable DC Power
600W – 5kW

Test: Low voltage DC accessories on board

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High Power DC Supply
5kW – 150kW

Test: DC-DC converter, stop/start vehicle electrical systems, regenerative braking, and electronic power assistance

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AC POWER SOURCES

Programmable AC Power
500VA – 9KVA

Test: EVSE AC supply source

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High Power AC Source
12KVA – 90KVA

Test: EVSE AC supply source

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Regenerative Grid Simulator
Up to 300kVA

Test: EVSE AC supply source, AC motor drive

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ELECTRONIC LOADS

Portable Benchtop DC Load
250W, 350W

Test: Low voltage DC-DC converters

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Modular DC Loads
Up to 2000W per mainframe

Test: Low voltage DC-DC converters

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High Power DC Loads
3kW – 24kW, up to 480kW

Test: High voltage DC-DC converters

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AC electronic load

AC Electronic Load
1.8KW – 4.5KW

Test: EVSE AC supply

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Electric Vehicle Battery Testing – Cell, Module, Pack

High precision, integrated battery test systems designed for lithium ion electric vehicle batteries or any chemistry. From R&D to battery production, Chroma’s battery test equipment provides advanced features including regenerative discharge systems that recycles energy from the battery back into the channels in the system or to the grid. Systems are configurable and flexible with multiple channel capabilities that can be upgraded as testing requirements change. In addition, the test system the finds charge rates, discharge rates, states of charge (SOC), states of health (SOH), and depths of discharge (DoD) with accurate measurements in voltage, current, temperature and power – statically and dynamically.

Battery Cell | Module
Programmable Charge/Discharge Tester

17011

Test: Battery cells, Battery modules, Capacitors, Ultra capacitors

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Battery Module
Programmable Charge/Discharge Tester

17020

Test: Battery modules, BMS, Fuel cells, Production testing, Components. Also performs battery and UUT collocation evaluation tests in advance that apply to the motor driver for vehicle stop/start systems, light EV electronic controllers, car mounted chargers, etc. This model can perform as a charge/discharge tester, a battery simulator or a bidirectional DC supply.

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EV Battery Pack Tester

Battery Pack
Regenerative Battery Pack Test System

17030

Test: High power battery packs, Production testing, Fuel cells, Capacitors, Ultra capacitors, Components, Generators, Stationary power. This model can perform as a charge/discharge tester, a battery simulator or a bidirectional DC supply.

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Battery Module | Pack
Regenerative Battery Test System

17040

Test: Battery modules, High power battery packs, Production testing, Fuel cells, Components, Generators, Stationary power. This model can perform as a charge/discharge tester, a battery simulator or a bidirectional DC supply.

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Multi-channel Battery Pack Simulator
Battery Simulation Software

17020 | 17030 | 17040

Test: Electric Vehicle battery and battery connected devices including motor driver, OBC, DC-DC converter or charger, and accessories within the DC bus

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Charger Testing – Electric Vehicle Supply Equipment (EVSE)

Chroma’s EVSE test system is the world’s first UL approved SAE J1772 EVSE Communication Protocol Automated Test System. This system simulates various states of an EVSE to validate charging compatibility before delivery to the vehicle.

Automated test - EV Charging equipment SAE-J1772

EV Charging Equipment (EVSE)
Automated Test System

Test: UL approved SAE J1772 EVSE Communication Protocol Automated Test System

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Regenerative Grid Simulator
Up to 300kVA

Test: AC EVSE, Charging stations

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Electrical Safety Testing

Electrical safety standards are increasing since new high-efficiency EV electronic components can drive up to 600V when in use. To insure safety to users, Chroma provides electrical safety test solutions for EV electronic product including wires and connectors, adapters, batteries and the charging system. As a result, you can be sure your products are compliant to standards and safe for the road.

Guardian Hipot Tester
Hipot 5kVac | 6kVdc
AC | DC | IR

Test: Electric vehicle component, EVSE, capacitors, and transformer compliance in accordance with UL, IEC, TUV standards

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Hipot tester analyzer

Guardian Electrical Safety Analyzer
Hipot 5kVac | 6kVdc
AC/DC/IR/GB/LC/Dynamic Function

Test: Wires, connectors, adapters, batteries, capacitors, and the EVSE charging system in accordance with UL, IEC, TUV standards

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Multi channel hipot tester

Guardian Multi-Channel Hipot Tester
Hipot 5kVac | 6kVdc
AC/DC/IR

Test: Electric vehicle component, EVSE, capacitors, and transformer. Conduct tests on up to 100 UUTs simultaneously

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Motors | Wound Component Testing

Electric vehicle motors are used for long hours and under varying environmental conditions where high durability and reliability are at risk. Temperature is a key contributor in the break down of insulation. If corona discharge occurs in turn-to-turn and turn-to-ground, it would cause the insulation to deteriorate due to the increased heat directly impacting the motor’s quality. Adding Corona Discharge Detection in hipot testing exceeds the quality requirements for insulation by detecting units with poor insulation early on. Thus, greatly reducing the defect rate caused by long-term usage.

Wound Component EST Analyzer
Hipot 5kVac | 6kVdc
ACWV | DCWV | IR | Impulse (Surge) | DCR

Test: High power motor standards like UL 1004-1. 500VA design is compliant with EC/UL output power requirements. EV motors, servomotors, ascension motors, transformers, solenoid valves, and stator surge testing

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Guardian Hipot Analyzer
5kVac/100mA | 6kVdc/20mA with 500VA output
AC | DC | IR | Corona Discharge and Discharge Level Analysis

Test: Provides useful data to verify the UUT’s insulation and increase the reliability of the product during manufacturing

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Impulse Winding Tester
10V~1000V impulse voltage test
0.1uH~100uH High/Low inductance test

Test: Apply to low inductance winding components with minimum 0.1uH inductance

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