The Importance of DC Power Supply in New Energy Vehicle Testing

DC power supply has irreplaceable core value in the field of new energy vehicle testing: as a precise and controllable energy supply device, its μs-level dynamic response capability can truly simulate battery charging and discharging conditions, and the 0.05% voltage accuracy ensures the reliability of BMS protection threshold verification; in the 800V high-voltage platform test, the 1500V insulation withstand voltage test capability is directly related to high-voltage safety; the bidirectional energy feedback characteristic reduces the energy consumption of the cycle test by more than 70%, and the ns-level switching speed supported by SiC devices can accurately capture the transient characteristics of the electric drive system. With the development of intelligent testing, DC power supply has been upgraded from a simple energy supply device to an intelligent test center integrating CAN communication and digital twin interfaces. Its technical parameters directly determine the effectiveness of test data and R&D efficiency.

The Technical Irreplaceability of DC Power Supply

1. Power quality determines test accuracy

(1) A voltage fluctuation of 0.1% in battery testing will cause the SOC estimation error to be magnified by 3 times, while the ripple suppression capability of high-end DC power supply (<50mV) far exceeds that of AC frequency conversion solutions;

(2) In the 800V high-voltage platform test, the ±0.05% voltage accuracy of the DC power supply can ensure that the insulation detection error is <0.1MΩ;

2. Dynamic characteristics shape the test boundary

(1) Modern BMS requires the power supply to complete 100-0% load switching within 100μs, and the traditional solution has a 300ms delay;

(2) The DC power supply supported by SiC devices can achieve ns-level switching response and accurately simulate surge/collapse under real working conditions.

Application Scenario Case Analysis

1. 800V high-voltage platform SiC device test

▶It is necessary to simulate 1200V/500A transient conditions to verify the switching loss of silicon carbide power modules. The DC power supply must have ns-level response capability to capture the voltage spike caused by dead time (typical value <50ns);

▶A certain car company uses a bipolar DC power supply to complete the insulation withstand voltage test of the 800V electric drive system, and the leakage current detection accuracy is 0.1μA at 1500V DC;

2. V2G bidirectional charge and discharge test

▶Use a programmable DC power supply to simulate grid fluctuations (±10% voltage deviation) to verify the seamless switching capability of the on-board charger in V2H mode. The switching time must be <100ms;

▶The test case shows that a DC power supply with energy feedback function can reduce the energy consumption of a 24-hour cycle test by 63%;

3. Simulation of extreme working conditions of power batteries

▶In a low temperature environment of -30℃, the DC power supply needs to maintain a current accuracy of ±0.5% to complete the verification of the battery low temperature heating strategy;

▶A battery factory adopts a multi-channel DC power supply parallel solution to achieve 2000A high current continuous pulse test (duty cycle 1:9), effectively evaluating the risk of lithium plating in the battery cell.

Solutions to Industry Pain Points

1. Breakthrough of test efficiency bottleneck

(1) The DC power supply system with integrated bidirectional energy feedback reduces the energy consumption cost of the 4-hour fast charging test by 82%;

(2) Modular parallel technology achieves a single machine output capacity of 3000A to meet the testing requirements of large-capacity battery packs for commercial vehicles;

2. Innovation of intelligent testing paradigm

(1) The power supply with built-in CAN FD protocol can directly parse the BMS message to achieve adaptive adjustment of the charging and discharging strategy;

(2) In digital twin testing, the μs-level data sampling rate of the DC power supply can build a high-fidelity virtual battery model.

Technology Integration Development Trend

1. High-voltage technology route

(1) In 2026, 1500V/500kW DC power supply will be mass-produced to support ultra-high voltage testing of solid-state batteries;

(2) Distributed power supply architecture realizes multi-DUT synchronous testing, and the test throughput is increased by 400%;

2. Reconstruction of test ecology

(1) 5G+TSN network makes the distributed power supply system latency <1ms;

(2) Quantum sensing technology pushes the current detection accuracy to pA level.