Advanced Test Solution for New Energy Parts – Chroma Multi-Channel Battery Simulator

Chroma ATE Inc. was invited to attend the IFEEC 2017 (International Future Energy Electronics Conference) held in Kaohsiung to introduce the new product for battery simulation. The battery simulator can perform simulations on the units that are critical to the booming EV industry such as DC charging pole, on-board charger, and DC/DC Converter, etc. for product verification.


Battery Simulator Soft-panel

As more and more energy conversion products such as motor driver, OBC, DC/DC convertor, and power conversion system (PCS), etc. use battery as the power source, a battery simulator is required for product quality verification. Battery suppliers may not be able to supply batteries of various kinds such as flow battery, sodium sulfur storage battery, and lithium-ion battery with different charge/discharge characteristic curves during product development.

The battery characteristic is nonlinear which is easily affected by temperature, charge/discharge current, aging cendition, and efficiency ,cannot replicate the same characteristic for repeat testing. As time is required to charge or discharge a battery, it makes instant output voltage change impossible for the real battery, which is quite inconvenient when testing the power converter’s upper and lower limits. Most importantly, the large capacity battery is big in size and will age after long-term use. It costs a lot for replacement, plus if the battery is damaged, overcharged or over discharged. It could easily cause safety hazards. In the lab, it is not recommended to set up large capacity batteries, but rather to use a battery simulator for testing.

What functions are required for a battery simulator?

  1. Battery internal resistance setting: The main task of a battery pack is to provide energy to the developed products. When the charged/discharged current is added to the battery pack, the voltage of the battery pack changes instantaneously in a short time due to the impact of the battery internal resistance.
  2. Battery capacity setting: The DC input voltage operating range should be clearly specified in the developed product specification, which is related to the battery pack capacity and output voltage.
  3. Battery voltage point setting: The usage of the battery pack varies with products, and the frequently seen battery management items are 6 voltage level including overcharge voltage, over discharge voltage, upper limit operating voltage, lower limit operating voltage, full charge voltage, and full discharge voltage.

Chroma’s multi-channel battery simulator is easy to use. The multiple embedded channels can test different DUTs at the same time, and read the test results in real time. The rapid setup of common battery parameter can simulate the charge/discharge voltage and IR state of a battery cell under normal, high and low temperatures. The battery cell parameters can convert battery pack state to set the operating and protection range. Moreover, it can set the initial state of output voltage for product testing and verification without waiting for the charge and discharge time like the real battery pack.


Battery Simulator Main Panel

For more information please visit our website http://www.chromaate.com/product/list/battery_pack_test_solution.htm

If you would like immediate assistance, email your requirements and preferred method of contact to Chroma ATE. Chroma is here to serve you.

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Battery Test Solution

Chroma’s 17040 regenerative battery pack test system reduces power consumption and provides dual modes for battery charge/discharge test and battery simulation to test battery connected devices.

Chroma ATE Inc., a leading provider of power conversion test equipment, announces the release of the 17040 Regenerative Battery Pack Test System. The 17040 test system is a high precision system specifically designed for secondary battery module and pack tests as well as battery simulation. It has a regenerative function to greatly reduce power consumption during discharge and ensure a stable power grid without generating harmonic pollution on other devices even in dynamic charge and discharge conditions. It is capable of recycling the energy discharged (Eff. >90%, PF >0.95, I_THD <5%) back to the grid reducing wasted energy that is discharged traditionally in the form of heat resulting in reduced HVAC requirements. The 17040 is available in four voltage (up to 1,000VDC) and current ranges with auto ranging, high accuracy current/voltage measurement (±0.05%FS/±0.02%FS), 2ms current slew rate, and 1ms data acquisition.

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Chroma’s 17040’s also have built in parallel channels and dynamic profile simulation functions. The parallel capability increases the charge and discharge current and power to its maximum, increasing its efficiency and flexibility. The dynamic profile simulation allows the user to load a battery waveform of a given drive profile in either current or power mode to meet NEDC/FUDS requirements. Its bi-directional architecture ensures that current will not be interrupted during the charge and discharge transition state so it provides an accurate simulation of driving conditions in line with ISO, IEC, UL and GB/T international testing standards.

The Battery Simulation mode is featured to test battery connected devices. When a connected device is under development, the 17040 can simulate the battery to verify whether or not the device is functioning as designed. In addition, the 17040 can control the SOC status of different batteries. Users can upload required battery curves to test the DUT for charge and discharge status. The 17040 can also perform battery and DUT collocation evaluation tests in advance that apply to the motor driver for vehicle start-stop systems, light EV electronic controllers, car mounted chargers, etc.

Multiple safety features are built in to the system including Over Voltage Protection, Over Current Protection Check, Over Temperature Protection, and external parameter detection to ensure protected charge/discharge testing on the batteries. Additionally, data loss, storage and recovery are protected against power failure.

Chroma’s Battery Pro software provides users with flexible test editing functions to perform independent channel tests, detailed reports in customizable formats, and abilities to meet various requirements of battery packs with high safety and stability. Software/hardware integration and customization capabilities include BMS, data loggers, chambers, external signals, and HIL (Hardware in the Loop).


(Battery simulator main panel, DCR setting, Battery characteristics V-SOC curve setting screen)

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