Improving the Quality and Safety of BMS

Zero carbon emission has vastly become a worldwide trend as the popularity of electric vehicles (EV) begins to grow; the battery is being the key component. The performance and safety of battery packs is critical to the EV; its core battery management system (BMS) needs to be thoroughly verified to ensure the battery’s safety.

▲ Chroma 8710 EV / Bus BMS ATS

Chroma 8710 BMS ATS provides battery cell voltage and temperature sensor simulation for battery management system; furthermore, it offers applications suitable for testing the UUT (unit under test) to reduce the problems when performing the tests. The inspection functions equipped by the system include:

  1. The BMS circuit designed power conversion circuit converts the starting battery voltage to the power required by digital circuit. It is necessary to confirm the power status to make sure that the control circuit works stably.
  2. Measurement accuracy is required when using high voltage to measure the battery pack total voltage. This voltage is also one of the judgment criteria for enabling insulation resistance. The inspection of insulation resistance is critical to safety requires verification. Besides supporting the verification, the best way is to perform calibration first and verification later.
  3. The high/low side drive circuit controlling the high voltage relay is also one of the vital items for verification. When an error occurs, if the high/low side gate drive circuit is not active to disconnect the charge and discharge circuit, it could cause safety problem and result in burning the electric vehicle. Therefore, it is necessary to check if the high/low side drive circuit is running normally under all kinds of conditions.

Chroma has in-depth research on battery management system that makes the 8710 BMS Functional ATS capable of fulfilling the above test requirements to perform a fully automated test procedure and long hour battery pack charging/discharging test.

Architecture Diagram of Chroma BMS

▲ Architecture Diagram of Chroma BMS

A battery management system usually comprises of a current sampling unit (CSU), a cell supervisory circuit (CSC), and a battery management unit (BMU) via CANbus to transmit signals and issue commands for operation. When verifying a battery management system, it is imperative to verify the cell status monitored by CSC as well as the active/passive balancing circuit and current consumption. For CSU, the validation of current sampling accuracy is essential as it may affect the battery SOC, SOH and overcurrent protection. As to the most complicate BMU that controls the entire system, it verifies the data returned from CSU and CSC.

Integrating with the test systems customized by Chroma can perform high quality functional verification on battery packs and battery management systems with provision of applications suitable for testing the UUT to reduce the trouble occurred during testing. For more information on the 8710 BMS ATS, please visit Chroma’s website below and list your needs and contact, we are happy to be of service.

More information please check on Chroma battery pack production line test

Implementation on Battery Management System Verification

Starting 2025, many countries around the world will begin a ban on the purchase of gasoline powered vehicles. As the policy grows closer to date, the development of the electric vehicle (EV) accelerates leading to a major breakthrough in battery technology. The battery plays an important role in improving the efficiency and safety of electric vehicles, and so does the battery management system (BMS).

 87001
▲ 87001 16CH Battery Cell Simulator

Best Tool for BMS Verification

The Chroma 87001 Battery Simulator is a powerful tool for verifying the battery management systems. It has voltage and current measurement and monitoring capabilities, providing 0~5V voltage regulation and 0~5A bidirectional current function per channel with simulation of voltage variation for 480 battery packs (2000V/4.2V) connected in series. The equipped output voltage control is convenient in testing upper and lower limits of battery operating range. It supports active and passive balancing circuit tests in 0~5A and 0~500mA two current ranges with measurement accuracy up to 0.02%F.S. For 0~5A range (power increase when paralleled), the accuracy is up to ±1mA with resolution up to 100uA that can meet the active balance design circuit test requirements. For 0~500mA range, the accuracy is ±100uA (0.02%F.S.) with resolution up to 10uA that can meet the passive balance design circuit test requirements. It is suitable for BMS circuit boards for measuring battery cell current consumption.

Significantly Reduce BMS Verification Costs

Certainly, the battery management system can also be used to verify the battery cell; however, it cannot maintain the same characteristics for repeated tests due to the influence of temperature, charging and discharging speeds, aging degree, and efficiency, etc. Moreover, setting up too many battery cells in the laboratory could raise safety concerns. In the past, the engineers connected several DC power supplies in series on their desk to test the cell supervision circuit (CSC) by manually adjusting the voltage and parameters, which took time and space, and the functions can be tested were limited. Using the Chroma 87001 Cell Simulator for testing became the better solution.

Easy-to-Integrate Devices with Complete Driver

The Chroma 87001 Batter Cell Simulator can be adapted to the battery management systems for electric vehicles, electric scooters, hand tools, and energy storage batteries. It has been applied to testbed for hardware in the loop (HIL) application by some system integrators. Chroma offers “easy-to-integrate device” and “complete driver” to give system integrators free of worries.

Chroma ATE transited its successful experience in the power electronics test industry to the battery test industry. After years of hard work and collaboration with major car manufacturers and battery pack factories, Chroma is capable of providing hardware devices and software tools to meet the test requirements through the know-how about the unit under test, reducing the trouble occurred during testing.

For more information on the 87001 Battery Simulator features and specifications, please visit Chroma’s website below and list your needs and contact, we are happy to be of service.  Model 87001 Battery Cell Simulator

Congratulations on Chroma Winning 2019 Taiwan Excellence Award

The results of 2019 Taiwan Excellence Awards have been announced. Chroma nominated 2 products with innovative value received the award.

Chroma 2238 Video Pattern Generator provides full 8K (7680×4320/8192×4320) resolutions @30/60Hz with up to 4 signal modules to meet various test requirements. The  VPG can output 4 different types of timings and patterns from each module simultaneously. Users can select the most suitable combination based on the desired application.

Chroma 17040 Regenerative Battery Pack Test System is a high precision, efficiency and safety charge/discharge system designed specifically for secondary battery module and pack tests. It has an energy regenerative function to provide clean and stable power back to grid with 90% efficiency to save energy and avoid heat consumption.

Chroma appreciates the recognition from the review committee of 2019 Taiwan Excellence Award. As an enterprise established in Taiwan, Chroma has long insisted on cultivating its own brand name globally. Chroma has branch offices in Europe, the United States, Japan, Korea, China, and Southeast Asia chartered to deliver innovative technologies with high value-added service to satisfy our global customers’ demands.

Click on the URL below to find out more information about our winning products.

2238 - Taiwan Excellence Award   17040 Taiwan Excellence Award

Chroma Battery Simulator – Leading Future Energy Development

Bidirectional DC-DC Converter Designated by IFEC as the Only Official Verification Tool

The IFEC 2018 (International Future Energy Challenge) sponsored by IEEE was held in Tsinghua University, Beijing. Ten teams from all over the world competed in the IFEC. The contest placed the top international students in power electronics and in the new energy generation field to compete. Chroma is the only officially designated test equipment provider for the IFEC and other sponsored competitions. For this year’s topic of “High-Efficiency and High Power Density Isolated Bidirectional DC-DC Converter for Residential Energy Storage Systems”, Chroma has tailored an automatic test system under the competition specifications.

The competitors must complete full charge and discharge efficiency tests, charge and discharge voltage ripples, overcurrent protections, and overcharge/undercharge test conditions. The Chroma 17020 Battery Simulator with built-in bidirectional DC power mode, independent multichannel design, high precision output and measurement specifications, DC input and output current switch without interruption, is suitable for testing the bidirectional DC-DC converters for incoming/outgoing shipment inspection and design verification, etc. Chroma, with innovative technical strength and expanding R&D resources to satisfy various front-end applications, was well prepared for the competition and earned high recognition from the committee.

During the IFEC 2018 finals, an international symposium “Future Power Electronics Technology” was also held for the first time to provide members a high-end communication platform. The speakers were formed by many renowned committee reviewers and IEEE associates. Being a leading company in the field of new energy solutions, Chroma shared in the R&D and testing of DC/DC converter test systems. This connected the industry development trends through practical and theoretical interactions and demonstrated Chroma’s long-term support and contributions in academia for fostering advanced talents.

About Chroma Model 17020 Battery Simulator

About IFEC IFEC is an international student competition sponsored by the Institute of Electrical and Electronics Engineers (IEEE) for innovation, conservation, and effective use of electrical energy, which is open to college and university student teams from recognized engineering programs in any location. It sets challenging topics to stimulate innovative thinking and aims to cultivate future elites in power electronics field. http://energychallenge.weebly.com/ifec-2018.html

New Generation of AC/DC Programmable Power Source for Server Power Supply Testing

The server market is steadily growing due to strong demands from cloud service providers and the expansion of next generation IT related infrastructures.

Mission critical server power supplies require testing and verification against stringent regulatory test standards to ensure operational efficiency of the server system. For instance, the immunity test standard includes voltage dips, short interruptions, and variations for both AC and DC as input requirements. Another functionality test includes simulating the transfer of input power from the main to backup system via UPS or HVDC system during abnormal power conditions (figure 1) to ensure dropout timing requirements are met.

61509
▲Figure1: Transfer of power during power loss condition

Chroma model 61509 (figure 2) is a high power density (5U height), 6kVA single- and three-phase output programmable AC Source capable of meeting rigorous test standards. With a maximum output voltage of 350Vac/495Vdc, the 61509 meets both AC and DC input voltage test requirements for server power supplies.

61509

▲Figure2: Chroma model 61509

Furthermore, the DC output power rating of the 61509 has been increased to 75% of the full rated output power and the control loop for individual coupling mode (AC, DC, AC+DC) has also been optimized to further extend test capabilities for AC/DC server power supplies. The 61509 is capable of delivering output frequency up to 2000Hz and possesses the ability to generate pure sine waveform output with typical distortion of less than 0.3% at 50/60Hz. These features make the 61509 ideal for commercial, power electronics, avionics, military, and regulation test applications from bench-top R/D design verification and quality assurance to mass production.

For more information on the Chroma 61509 features and specifications, please visit Chroma’s website: Programmable AC Power Source Model 61509/61508/61507 

High Voltage Grid Simulator Adds PV Inverter’s HVRT Test Function

As photovoltaic industry policies continue its growing support for distributed solar power systems, commercial power generation equipment demands for 20kVA-100kVA inverters increase as well. With the development of grid-connected high-voltage 600Vac-800Vac (VLL) systems to reduce cost and increase power generation efficiency, an important challenge to manufacturers is the inverter’s stability in high-voltage grid connections. The newest high-voltage 1385Vac (VLL)/120kVA regenerative grid simulator released by Chroma meets the specifications for inverter quality verification and grid performance tests, such as LVRT, HVRT, harmonics, waveform distortion, 3-phase unbalance, voltage dips, short interruptions, and voltage change immunity tests.

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61800_ac_load_4_tc

The latest UL1741 SA specification for inverter design must be able to run under HVRT test without off-line operation. In addition, it must have the capability to continuously adjust the power and infuse reactive current into the power system during high voltage ride through. So, when the inverter is designed for a normal rated voltage of 690Vac (VLL), it must be tested for rated grid voltage (over 897VLL) which is raised 1.3, 1.2, or 1.1 times respectively as it has to run uninterruptedly at dozens of test points during voltage rise and recovery. Moreover, it has to respond normally and issue a proportioned capacitive reactive current according to the standard during HVRT, which can effectively stabilized the grid voltage and ensure the demand for the quality of electricity.

Chroma’s high-voltage power grid simulator can output voltage up to 1385VLL (800VLN) without using a step up transformer. Besides up to 1.5V/us output voltage transient capability, it has flexible, cost-effective and space-saving features. For example, when testing an inverter below 50kVA, it can be used as two 60kVA power grid simulators; and if high power and high voltage 60-100kVA inverters are required for testing, two 60kVA power grid simulators can be connected in series for up to 1385VLL (800VLN).

For more information about Chroma 61800 features and specifications, please visit Chroma’s website: Chroma 61800 Series Regenerative Grid Simulator

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Chroma Collaborates with the National Taiwan University of Science and Technology to Help Improve Al and Green Industry Technologies

On March 26th, 2018, Chroma ATE Inc. collaborated with the National Taiwan University of Science and Technology (NTUST) to hold a signing ceremony in efforts to engage the electronics industry to actively participate in an international industrial-academic alliance. The organizations seek to advance the research and development of innovated technologies associated with sustainable energy, AI artificial intelligence, smart manufacturing, etc.

Since 2015, Chroma has invested over 15 million NT dollars along with other various instrumental equipment (valued at 4.2 million NT dollars) to the Chroma NTUST R&D Center in efforts to help cultivate the academic aptitudes of NTUST students.

Chroma_eNews_20180326

Benjamin Huang (left), Deputy GM of Chroma, and Ching-Jong Liao (right), president of NTUST, in the signing ceremony of the cooperation agreement. (Photo provided by NTUST)

Ching-Jong Liao, President of the NTUST, stated that the university is capable of customizing multiple solutions to different business demands by providing the research and development necessary to the AI and green industries. Liao plans on further expanding industrial-academic relationships to the global level by broadening the markets of domestic manufacturers internationally and linking R&D energy with transnational scientific research institutions and industries.

For many years, the NTUST has been actively collaborating with Germany, United States, and Japan in the industrial-academic movements. In addition, the university holds a great deal of alumni resources spanning internationally from countries including the United States, Indonesia, Vietnam, and Ethiopia who are assets in promoting industrial-academic cooperation.

As a world-leading supplier of precision Test and Measurement Instrumentation, Automated Test Systems, Smart Manufacturing System, and SmartAuto Total Turnkey Solutions, Chroma invests a significant amount of resources into R&D. This substantial investment of resources ensures that Chroma remains competitive on the forefront of leading technologies and integration capabilities in the optics, mechanics, electronics, thermal control, and software industries. And with the help of the NTUST, Chroma is able to quickly grow as an organization that continues to develop and harness advanced technologies.

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New Regenerative AC Load Function – Further Extend the Grid Simulator Capability for Micro-grid Test Application

The Chroma 61800 Series high power regenerative grid simulator capable of delivering output power up to 300kVA has been widely used for testing PV inverters, power conditioning systems (PCS) and EVSE charging stations. Lately, more and more engineers are studying the applications of micro-grids and energy storage systems. The 61800 Series not only can simulate the voltage and frequency test requirements for different regions of world, it is also capable of simulating voltage transient and abnormal conditions with synthesis of harmonic / inter-harmonic components as well. Its full four quadrants operation capability and regenerative function used to feed the energy back to the grid are the most favored by users.

Aside from the aforementioned capabilities to simulate the AC voltage test conditions, the capabilities of simulating various load conditions in order to cope with the diversified and dynamic nature of the system are also required for the micro-grid testing. It is very rare in the market to have test equipment with both AC source and AC load functions as a single unit.

Traditional AC electronic load designs mainly consist of passive and switch devices. These electronics loads can only operate in the 1st quadrant (both voltage/current in the positive region) and 3rd quadrant (both voltage/current in the negative region). The functionalities for the traditional AC electronic load are mainly limited to CR mode and rectified mode due to the design’s nature. Unlike the traditional electronics load, Chroma 61800 Series with full four quadrants and a regenerative design has further extended its test application capabilities by including the regenerative AC load function as an option with its maximum loading capability equivalent to the maximum output power rating of the unit. For instance, with the AC load option installed, the 61800 Series is capable of providing up to 180kW loading capability.

The phase lead/lag mode with phase angle setting ranging from 90 degree ~ -90 degree will simulate the corresponding voltage and current condition under an inductive or capacitive type load (see below waveforms). When the phase angle setting is in the range of 90.1 degree ~ 180 degree (-90 degree ~ -180 degree), the 61800 will become a current source, similar to a programmable inverter which is applicable for micro-grid related testing.

61800_ac_load_3_en.jpg

The Chroma 61800 Series regenerative AC load function is applicable for AC power supplies, UPS, PCS and EVSE charging station (V2L/V2H) test applications. It can simulate the effects of different loading conditions based on various home appliances, or test the PV inverter’s power quality correction functionality by deliberately setting the AC load in various reactive load conditions. The regenerative AC load is applicable for simulating the various power flow conditions related to micro-grid application for research in smart management or for balancing supply and demand loads.

Chroma uses the DSP digital control method to add the optional AC load function to the 61800 Series regenerative grid simulator. The AC load function further diversified the 61800 Series test applications ranging from academic, R&D design verification, and quality assurance to mass production.

For more information on the Chroma 61800 features and specifications, please visit Chroma’s website:   Regenerative Grid Simulator Model 61800 Series

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Introducing the newest Chroma ATE Solutions APP. Download and experience it now.


Android Download iOS Download Chroma ATE Inc.

Chroma ATE Inc. is introducing its new digital service to provide you information for test and automation turkey solutions via the app. Significant markets Chroma serves include electric vehicle, LED, photovoltaic, green battery, semiconductor, photonics, flat panel display, video and color, power electronics, passive component, electrical safety, thermoelectric, automated optical inspection, and intelligent manufacturing system for smart factory.

This app covers 14 test solutions and over 500 product models in 3 languages. Synchronizing to the on-line inquiry system, you can get help from Chroma sales offices at your fingertips. The global service map provides you with GPS navigation, phone call, e-mail contact, and website browsing functions. Find the service points near you anytime, anywhere. Click or Scanning QRcode to get the free Chroma ATE Solutions APP now!

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Chroma Launches Its New 63000 Series DC Electronic Loads to Satisfy the Tests for Small Power Supplies and Batteries

Chroma 63000

To meet the testing requirements of small power supplies, Chroma has launched a brand new 63000 Series of benchtop DC electronic loads specifically designed for testing lower power adaptors, cell phone chargers, small batteries (such as cell phone batteries), D/D converters, USB PD, and so on. Different from the modular electronic load, they can be used without a mainframe. With the advantages of its compact size, lighter weight, low cost, and portability, the 63000 Series is the perfect electronic load for R&D labs and colleges.

 Chroma 63000

The voltage and current specifications of each model in the 63000 Series are comprised of three settings and three measurement ranges. For adapters and USB PD’s that require higher testing accuracy, small current test like 0.1A is often performed during efficiency testing. However, misjudgment frequently occurs due to insufficient range or low accuracy. The minimum setting and measurement current range of the 63004-150-60 is 2A and the current error is less than 2mA which makes it suitable for these tests and validating the regulatory compliance of Energy Star. The maximum current output of a single load is up to 60A, with power up to 350W. Besides, the large scaled fonts and moderate shortcuts in its 3.5” LCD display bring great usability in the forms of sight and touch.

Chroma 63000 LCD screen

In addition to the basic CC, CR, CP, CV, and CRD modes, the 63000 Series also has battery discharge, User Defined Waveforms (UDW), and programming functions to satisfy the test requirements for D/D converters, 3C battery dischargers, and switching power supplies.

The battery discharge mode is applicable for 3C battery discharge test and can record the Wh (Watt) and Ah (Ah) during battery discharge. The User Defined Waveform (Figure 1) can simulate the real load current allowing the R&D test engineer to verify the power in the actual load current. The quality assurance department can reproduce the actual load current situation to reduce the development and validation time. For other DC power and component applications such as fuel cells, fuses, switches, and wiring tests, the pulse current (Figure 2) function is provided to test them by setting the repeat time to 1 in the existing dynamic loading mode.

 

Chroma 63000 wave
   Figure 1 User Defined Waveform Figure 2 Pulse Current

With over 30 years’ experience manufacturing test and measurement instrumentation, Chroma continues to create innovative power electronics testing solutions and provides the industry with highly reliable and high performance testing instruments.

For more information about our DC Electronic Loads – 63000 Series, please visit our company website: DC Electronic Load Model 63000 Series

If you would like a product demonstration, email your requirements and preferred method of contact to info@chromaate.com. Chroma is here to serve you. 

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