How To Test the Three-Electric System of New Energy Vehicles?

As an essential means of transportation, cars are becoming increasingly integrated into our lives. With growing global environmental awareness, new energy vehicles have become a key trend in the automotive market. The future of new energy vehicles will be global.

After several years of development, my country's new energy vehicle industry has continued to grow, and the irreversible trend of new energy vehicles has essentially taken shape. So, as a consumer, are you still struggling to decide whether to buy an electric car or a gasoline car? What are the safety risks of electric cars? What if the battery dies during a long, high-speed drive? What is the expected battery life? If I buy an electric car, has it undergone factory testing? Is it a qualified vehicle? If you have any of these concerns and questions, then read on. This article will explain how the three core systems of new energy vehicles are tested.

First, we need to understand the key components of new energy vehicles.

The three major components of new energy vehicles are the battery, the motor, and the electronic control system, commonly known as the "three-electric system." These are also the three core technologies of new energy vehicles. They play a vital role in their safety, and the quality of the "three-electric system" directly affects the vehicle's performance and price. Power batteries are the primary energy source for new energy vehicles and are crucial to their success. Power batteries are the driving force behind electric vehicles, and the choice of battery directly impacts the overall vehicle performance. Key performance indicators for electric vehicle power batteries include energy density, power density, and cycle life.

How should power batteries, the primary energy source, be tested?

As a crucial component of new energy vehicles, batteries will remain a constant, regardless of their development. However, both vehicle manufacturers and component manufacturers do not always use actual batteries for testing.

Because batteries are inherently heavy, inherently inconsistent and pose safety risks, and lack flexibility due to the inability to input multiple voltages for simulation, most customers use battery simulators instead of actual batteries for various tests.

So, let's take a look at what a battery simulator is, what its purpose is, and what are the characteristics of a battery simulator?

1. Definition

A battery simulator is a product of the development of new energy vehicles. It combines battery and photovoltaic simulation functions, simulating the charge and discharge characteristics of power batteries to meet the testing requirements of new energy vehicle components or systems such as motors, electric drive systems, complete vehicle systems, and energy storage converters. It can also simulate the characteristics of photovoltaic panels to meet the testing requirements of photovoltaic inverters.

2. Function

A battery simulator simulates the output state and charge and discharge characteristics of a real battery. Test conditions such as battery SOC, depth of discharge, open-circuit voltage, and internal resistance can be adjusted at any time according to user needs, allowing rapid verification of the device's response under different battery conditions.

Testing motor controllers, drive motors, and complete vehicles in the new energy electric vehicle industry is a typical application of battery simulators. Battery simulators are widely used in production lines, laboratories, and other environments.

3. Features

The battery simulator utilizes high-frequency PWM rectification technology, bidirectional DC conversion technology, and FPGA digital control technology. It features bidirectional energy flow, seamless forward and reverse switching, and grid adaptability. It also features programmable protection parameter settings and output parameter limit settings to better protect the safety of the device under test.

1) A battery simulator is an all-in-one photovoltaic and battery simulator.

2) To meet the needs of new energy vehicle testing, it features high voltage, high current, and a wide output range.

3) It has a built-in grid regenerative function, providing continuous energy regeneration at full power.

4) It features battery simulation, supporting the characteristics of various battery types, including lithium, nickel-metal hydride, and lead-acid batteries, and includes battery temperature compensation.

5) It features a programmable output waveform, facilitating data analysis.

6) It features a programmable output ramp function, reducing voltage shock to customer equipment.

Using a battery simulator is a safe option for testing new energy vehicles. It not only shortens product testing time but also creates a safer testing environment.

Compared to testing with actual batteries, a battery simulator can simulate the voltage and current output of various lithium batteries, producing more consistent and repeatable test results and enabling data analysis. Once a product passes all tests, its safety and compliance are generally guaranteed, eliminating concerns about battery explosion.