Background
According to the requirements of China's National New Energy Vehicle Development Plan(2021-2035),Electric Vehicle becomes themain part of Automobile industry.To ensure on-road safety,charging safety,and driver safety with electric vehicles,in-use electric vehicles should be tested and evaluated using effective and pragmatic methods.
Video: The Process of EV Test Solution
Test Process
The solution encompasses two core parts: charging detection and discharging detection. Charging detection, also referred to as static detection, primarily assesses the performance of potential equalization and the insulation resistance of the charging port. Discharging detection, known as dynamic detection, mainly evaluates the safety of the power battery, the drive motor, and the electronic control system.
SL
|
|
Test Item
|
Value
|
Standard
|
Result
|
|
Test ltem : Power Battery Safety
|
|
1
|
Charging
|
Max. Temperature of 8 attery
|
31
|
≤60℃
|
PASS
|
|
2
|
Max, Voltage of Secondary Cell
|
374
|
≤4.5V
|
PASS
|
|
3
|
Secondary CellValtage Range
|
000
|
≤0.3V
|
PASS
|
|
4
|
Discharging
|
Max.Temperature of Battery
|
31
|
≤65℃
|
PASS
|
|
5
|
Min.Voltage of Secondary Cel
|
352
|
>1.8V
|
PASS
|
Test Item：Driving Motor Safety
|
|
6
|
Driving Motor Temperature
|
600
|
≤175℃
|
PASS
|
|
7
|
Motor Controller Temperature
|
550
|
≤95℃
|
PASS
|
|
Test Item：Electrical Control System Safety
|
8
|
DC/DC Converter Temperature
|
400
|
≤95℃
|
PASS
|
Test Item :Electrical Safety
|
|
9
|
DC Charge Insulation
|
4515014.6
|
≥100Ω/V
|
PASS
|
|
10
|
AC Charge Insulation
|
1096.5
|
≥1MQΩ
|
PASS
|
|
11
|
Poterntial Equalization Between Shell&E Platform
|
0.07
|
≤0.10Ω
|
PASS
|
|
12
|
PentialEqualization Between Shells
|
0.02
|
≤0.20Ω
|
PASS
|
|
Remark：This is the screen shot of actual test report based on China technical regulation, and it shall be different case by case due to the different regulation and technical condition.
|
Core Configuration
EV Charging Safety Tester(CCS-2 type)
Introducing the Cosber’s EV Charging Safety Tester,designed for electric vehicles with European CCS-2 charging standards.Thisadvanced equipment offers comprehensive testing and monitoring capabilities,including high voltage insulation checks,potentialequalization assessments,and BMS communication analysis.Additionally,it functions as an AC/DC EV charger,providing versatility and convenience in one device.
Detection Function
|
Test Function
|
Value Range
|
Standard
|
|
SOH
|
0-100%
|
≥70%
|
|
DC Charge Insulation
|
0-2000KΩ/V
|
≥100Ω/V
|
|
AC Charge Insulation
|
0.1-1000MΩ
|
≥1MΩ
|
|
Potential Equal. btw. EV and P.E
|
0.01-20Ω
|
≤0.1Ω
|
|
CCS-2 type DC charging capacity
|
0-30kW
|
|
Equipment Parameter
Operational Power
|
AC 380V+10%，50/60HZ+5%
|
|
No-Load/Full Load Power Consumption
|
0.2/30kW
|
|
Operational Environment
|
Temperature:0~40?°C;Humidity:20~90%RH
|
|
Dimension(WLH)
|
600×600×1600mm
|
|
Equipment Weight
|
150Kg
|
Z-Shaft Interlinked 4WD Dynamometer for EV
Patented Z-Shaft interlinked Dynamometer designed for all types of EVs with different
drive modes:Front-wheel-drive,Rear-wheel-drive,and Four-wheel-drive.
|
|
Real-time synchronisation of four-wheel drive is achieved through automatic wheelbase
adjustment(2300-3300mm).Simply input the value of wheelbase can automatically adjust the front and rear rollers bench via the Z-shaft transmission.
|
Why 4WD Synchronized
|
Most of the 2WD EVs have high-accuracy wheel traction control.However,if the four wheels are not moving at th same speed,power take-off of the EV could be limited orsuppressed.
|
|
|
For All-Wheel Drive(AWD) EV,the front wheels and rear wheels are usually powered by two different motors with different power grades.As a result,the front wheels and the rear
wheels will not have the same speed during a regular DYNO test.
|
|
To address this issue,we must use the interlinked 4WD Dynamometer for a perfect simulation of the synchronousoperation of wheels during testing.
|
EV Dis-charging Test Functions
|
Discharging Simulation
|
|
BMS Monitoring and Driving
Capacity test
|
|
EV Output Power and Electric Regenerative
Braking System Test(Optional)
|
|
4WD Cycle Running at 0-130km/h on the
Dyno chassis for the Battery Discharge Simulation.
|
Real-time monitoring of EV's driving state during
the Dyno test(via EV-OBDor Dashboard).It is also
capable of testing the stability of an EV's driving
under specified conditions.
|
EV output power test is conducted under a synchronous
4WD running condition.
Comparison of drag power test for ERBS of EV during its
cruising cycle(optional).
|
Dyno Bench Technical Data
|
Item
|
4WD EV Dyno(Z-Shaft Linked)
|
|
Maximum carrying vehicle mass
|
5000kg
|
|
Maximum bearing Axle mass
|
3000kg
|
|
Maximum absorption driving force
|
0〜6000N×2
|
|
Power test speed range
|
0-200km/h
|
|
Roller diamete
|
Ф216mm
|
|
Roller length
|
1000mm
|
|
Center distance of rollers
|
442mm
|
|
Wheel diameter
|
500〜800mm
|
|
Inside wheel thread
|
700mm
|
|
Outer wheel thread
|
2700mm
|
|
Minimum vehicle wheelbase
|
2300mm(with a design option of 1800mm)
|
|
Maximum vehicle wheelbase
|
3300mm(with a design option of 2800mm)
|
|
Basic inertia
|
907kg
|
|
Eddy current rated power
|
160kW × 2
|
|
Back drag motor power
|
7.5kW to 05km/h
|
|
Compressed air pressure
|
0.6〜0.8MPa
|
|
Equipment pitwork Dim.LWH
|
4000*4330*550mm
|
Software UI
|
|
Dis-charging/Charging Test Software
|
Dis-charging Test Interface
|
|
|
|
Charging Test Interface
|
EV Test Operation Info. System
|
General Q&A
Q: Is the OBD device available for any EV mode?
A: No, OBD is based on whether the OBD protocol of the EV, and without it, OBD can not be programmed and used.
Q: What is the use of the OBD?
A: It is used to read the data from the MCU&ECU via OBD port during the dis-charging test.
Q: Why the dynamometer is necessary in the solution?
A: To do the dis-charging test, it is important to make the actual driving simulation.
