Dynamic DC Emulator Efficient testing of charging technology and power electronics

Dynamic DC Emulator Efficient testing of charging technology and power electronics

Highlights Efficient testing of charging technology The Scienlab ChargingDiscoverySystem (CDS) can be combined with the Dynamic DC Emulator (DCE) for emulating any electric vehicle or a universal DC charging station. The CDS covers the relevant norms and charging standards (ISO 15118, DIN SPEC 70121 etc.) in this context. The coordination of the test systems resulting from single-source production, the high dynamic response, and the response times required for testing timings guarantee efficient testing. Energy-efficient source and sink mode Bi-directionality enables the DCE to be operated as a source or sink. The voltage and current controllers required for this are already implemented and can be parameterized as desired via the customer interface. The DCE is also recuperative, which permits highly efficient and cost-effective operation. Precise and reproducible measurement results The high quality of the measuring and control unit as well as the power electronics in robust EMC design guarantee maximum reliability of use as well as precise and reproducible measurement results. Real-time capable, open interface The DCE offers openly documented interfaces (Ethernet, EtherCAT) as a fast, flexible and easy means of connecting to any automation tools or Hardware-inthe-Loop (HiL) test environments. Powerful FPGAs and microcontrollers ensure a real-time capable interface for time-synchronous test bench control and measurement data evaluation. Compact and modular design The compact design of the system makes it quick and easy to transport. The modular design also enables up to four 22 kw systems to be connected in parallel. This means that the DCE can also be used to test higher-performance DUTs. Retrospective parallel connection is also possible, guaranteeing futureoriented research and development. Dynamic DC Emulator Efficient testing of charging technology and power electronics The major challenge in developing and producing electronic systems is having to comply with different standards worldwide in order to guarantee faultless operation. The steady growth of the electric mobility segment also means an increasing focus on communication between the vehicle and charging infrastructure. The Dynamic DC Emulator (DCE) can emulate both the vehicle and the charging infrastructure, which means that not only the communication but also power flows can be tested under realistic conditions during development. With the DCE as a freely programmable power source and sink, the system can cover all applications in the automotive and industrial fields as an all-in-one system. With this solution, Scienlab offers a flexible and efficient high-end product which is developed and produced at our Bochum site, deploying our long-standing expertise and patented solutions in the field of power electronics. Fields of application Testing of high-voltage power electronic components and systems that have to undergo comprehensive testing for maximum failure safety, energy efficiency, control and measurement accuracy as well as quality, for example for use in the automotive sector. Bi-directional mode enables electric vehicles (EV) to be emulated as a sink or charging infrastructure (EVSE) as a source in order to investigate their interoperability in combination with the Scienlab ChargingDiscoverySystem (CDS). Validation of DC charging processes 2

Dynamic DC Emulator The right solution for every application Thanks to bi-directionality, integrated DC voltage and current controllers, high dynamics, and the regenerative energy feedback capacity, the Scienlab DC Emulator offers all necessary functionalities for the efficient and effective testing of all power electronic components in EV and EVSE. EV and EVSE emulation Communication between the systems involved in charging plays an important role alongside the power electronics of these charging systems. A successful charging process requires the exchange of information between the charging station and vehicle in order to synchronize the maximum permitted charging power and other limit values of the systems, for example. When combined with the Scienlab ChargingDiscoverySystem (CDS), the DCE is transformed into a comprehensive test environment for the charging interface of all common electric vehicles and charging stations. Details on comprehensive testing of the charging function and interoperability can be found in the Scienlab product brochure for the ChargingDiscoverySystem. Emulation of active DC sources and sinks To be able to test the output side of DC sources such as charging stations or inverters for operation with different loads, it must be possible to emulate various DC loads. When used as an DC current source, the DCE can also serve as a programmable load in combination with voltages applied externally. The energy can be fed back directly into the network, permitting a reduction in the (sometimes high) energy costs. All the parameters required to emulate the load can be changed during operation. When testing high-voltage components such as DC/DC converters or chargers it is a benefit to not be restricted by the state of charge, temperature, or aging of a real battery. This can be avoided by emulating a high-voltage battery, which also does away with all safety-related risks of an undesired thermal or chemical reaction. When used as a DC voltage source, the DCE from Scienlab can replace any high-voltage battery (e.g. lithium ion) during testing. Freely parameterizable variables such as the open circuit voltage and impedance can be changed manually or via internally or externally calculated battery models at runtime. The high system dynamics mean that voltage drops, for example, can be emulated within milliseconds. Battery models suitable for immediate use can be supplied directly on request. 3

Flexible integration into different test environments The Scienlab Dynamic DC Emulator (DCE) can be flexibly in - tegrated into different test scenarios as appropriate to the application. When using the DCE as a standalone test system, it is controlled using the Emulator Control PC software. If the DCE is used in combination with a ChargingDiscovery System (CDS) for tests in the area of charging technology, it can be controlled using the ChargingDiscover software. The DCE can also be integrated into a Hardware-in-the-Loop (HiL) test bench. Here the HiL system can directly access the appropriate parameters and functions via the open interface. Operation via the Emulator Control software The Windows-based PC software Emulator Control is used to manually control individual emulators or a network of emulators in the test bench. The Scienlab software is precisely tailored to the customer applications and the desired test bench functionalities. The user can see all the relevant electrical model parameters at a glance. The data can also be imported and visualized at any time. In addition, the software can be used to administer complete parameter sets and system messages, supports flexibly programmable voltage curves, and has an integrated service area. Important software functions: Measured value output/scope view Visualization of error and system messages Storage and loading of complete parameter sets and user layouts User interface of the Scienlab software Emulator Control 4

Dynamic DC Emulator Operation via the ChargingDiscover software In the field of charging technology, the DCE can be controlled via the ChargingDiscoverySystem (CDS) in combination with the Windows-based ChargingDiscover PC software for communication and performance tests. The CDS tests the functionality and interoperability of all the components involved in the charging process by emulating the charging communication of the EV and EVSE. At the same time, the electrical parameters are measured and checked for compliance with the standards. Test sequences can be defined freely and subsequently performed manually or automatically via the ChargingDiscover PC operating software. The software is used via application-specific user screens that provide the user with all necessary control elements and test parameters according to the selected use case (EV or EVSE test). The software also comprises all necessary functions for the visualization and evaluation of individual messages and measured values as well as for the automatic generation of reports. User interface of the Scienlab software ChargingDiscover 5

Integration into a HiL test environment In addition to designing standalone systems or fully outfitting laboratories, Scienlab also offers hardware-in-the-loop (HiL) test environments. When integrating an DCE into a HiL system, it can be integrated both into existing test benches as well as new test bench designs for various fields of application. The systems are connected with ease to the customer interfaces (e.g. EtherCAT, Ethernet) using openly documented protocols. Over and above the charging process, the DCE can be integrated into a Scienlab Power HiL test environment in order to emulate peripherals such as vehicle electrical systems or a residual bus simulation. Further possible components of such a test environment are the Dynamic AC Emulator (ACE) and the ChargingDiscoverySystem (CDS). Dynamic AC Emulator (ACE): The ACE is used if AC charging is also to be supported. The ACE works both as a AC voltage source and a AC current source and can therefore emulate any sources such as universal AC charging stations with current limitation. Since each phase can be configured independently of the others, it enables worldwide grid structures to be emulated. The required ACE configuration can be adapted in terms of voltage, current, and power as appropriate to the customer's wishes. With initial values of up to 480 V and ±128 A rms, the system is optimally designed for the requirements of the automotive sector among others. ChargingDiscoverySystem (CDS): The CDS tests the functionality and interoperability of all the components involved in the charging process by emulating the charging communication of the EV and EVSE. At the same time, the electrical parameters are measured and checked for compliance with the standards. Test sequences can be defined freely and subsequently performed manually or automatically via the ChargingDiscover PC software. The CDS also assumes synchronized triggering of the power sources and sinks (DCE) within a HiL test environment. Integration into a HiL test environment Emulation of mains supply DUT EV/EVSE emulation Dynamic AC Emulator or ChargingDiscovery System Dynamic AC (DC) Emulator HiL (option) Charging Discover 6

Dynamic DC Emulator Technical data of the Scienlab Dynamic DC Emulator Output power Control modes ± 11/22/44 kw (additional power increase possible through parallel connection) Current control, voltage control Energy conversion efficiency Up to 90 % Output voltage U Max. output current I Measuring accuracy U Measuring accuracy I Voltage dynamics Voltage ripple Cycle time Interfaces Dimensions of desktop unit/system cabinet (depth x width x height) Weight 600 or 1,000 VDC ±50, 100, 200 A ±0.05 % of measured value ±0.02 % of measuring range ±0.05 % of measured value ±0.04 % of measuring range 100 V 200 V < 1 ms < 500 mv rms 1 ms Ethernet, EtherCAT 600 x 560 x 1,100 mm / 800 x 800 x 2,630 mm Approx. 100 kg, 22 kw each Texts, photos and graphic designs in these documents are protected by copyright. Use, dissemination or reproduction is permitted only subject to prior agreement by Scienlab electronic systems GmbH. 7

P-DCE-1E-517 Scienlab electronic systems GmbH Lise-Meitner-Allee 27 44801 Bochum Germany phone +49 234 41 75 78 0 fax +49 234 41 75 78 10 web www.scienlab.de mail info@scienlab.de