On Board Charger (OBC) Testing for Electric Vehicles (EVs) · On Board Charger (OBC) Testing for...

On Board Charger (OBC) Testing for Electric Vehicles (EVs)

Rev 2.2

Speaker: Dr. Alessandro Pevere

Main author: Eng. Roberto Moncada

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Table of contents

1. Introduction

MSY Product portfolio

MSY e-Mobility Overview

OBC features

OBC V-Cycle

HIL Strenghts

2. HIL setup

Environment

HW configuration for OBC testing

Charging plant model

OBC real time Integration

CANoe OBC control panel

3. Smart charge

Main standards

PLC ISO 15118

CHADeMo/DC China

4. OBC testing

System test procedure

System test tool chain

Traceability

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Introduction - TOC

1. Introduction



OBC features

OBC V-Cycle

HIL Strenghts

2. HIL setup

Environment





3. Smart charge

Main standards

PLC ISO 15118

CHADeMo/DC China

4. OBC testing



Traceability

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Introduction - MSY Product Portfolio

On Board Battery Chargers

DC/DC Converters for Electric & Plug-in Hybrid Vehicles HVAC Heating, Ventilation & Air ConditioningAutomatic Gear Control

Alarm & AntitheftSystems

Parking Sensors and Distance Control Parking Space Measurement Systems

Insurance Telematics Black Boxes Insurance OBDs Devices

SVR - SVT - OE Telematics Units

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Introduction - MSY e-Mobility Overview

OBC Gen I_UCX I

3.5kW-50 kW

Fast Charge 50kW

Udc : 250-410V

Eff : 95% *

Liquid cooled

Weight =7.5kg

OBC Gen II_UCX II

7kW-50 kW

Fast Charge 50kW

Udc : 250-410V

Eff : 95% *

Liquid cooled

Weight =9,5kg

CCU (OBC+DC/DC)

Innovation

22kW (1-3ph)

DC/DC : 3,5kW

Udc : 210-400V

Eff : >95%

Liquid cooled

Weight <17kg

Combi Gen II

OBC+DC/DC

3.3kW-6.6kW

DC/DC: 2.2kW

Udc : 210-410V

Eff : 95% *

Liquid cooled

Weight <10kg

MSY Gen III

OBC lightweight

3.6kW (1ph)

Udc : 210-410V

Eff : 95% *

Liquid cooled

Weight <5kg

MSY Gen III OBC

22kW (1ph-3ph)

Udc : 210-800V

Eff : >95% *

Liquid cooled

Weight <15kg

MSY Gen II

OBC Cina

7,2kW (1ph)

Udc : 210-410V

Eff : 95% *

Liquid cooled

Weight <9kg

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Introduction - OBC features

AC/DC power conversion

Communication with EVSE (PLC, CAN,…)

Vehicle Plug control (Pilot, Proxy, Lock, Flap…)

Communication with EV (CAN, LIN, Ethernet,…)

Charging interfaces management (LEDs, pumps, relays,…)

AC and DC charge management

Water cooled

EVSE EV

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Introduction - OBC V-Cycle

Calibration

Calibration

Bench testing

Requirement

Analyses

OBC

V-Cycle

(ISO 26262)

Function design

Code design

DOORS

Design

Function testing

Model-In-the-Loop

Code proprieties

TargetLink config TL

Code testing

Software-In-The-Loop

Automatic

code generation TL

Basic SW

design

Integration

and

merging

Test

requirements

Bench

Testing

Hardware-In-the-loop

Testing

Testing and

measurement analysis

Final testing

Basic SW

coding

and

mergeAutomatic test

Commissioning

matching

Architecture design

module design

Static code analysis

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Introduction - OBC V-Cycle

Calibration

Calibration

Bench testing

Requirement

Analyses

OBC

V-Cycle

(ISO 26262)

Function design

Code design

DOORS

Design

Function testing

Model-In-the-Loop

Code proprieties

TargetLink config TL

Code testing

Software-In-The-Loop

Automatic

code generation TL

Basic SW

design

Integration

and

merging

Test

requirements

Bench

Testing

Hardware-In-the-loop

Testing

Testing and

measurement analysis

Final testing

Basic SW

coding

and

mergeAutomatic test

Commissioning

matching

Architecture design

module design

Static code analysis

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Introduction - HIL Strenghts (1/2)

- Deterministic execution

A deterministic execution will always produce same output from a startingcondition.

- Automation of the process

Using scripts numerous tests can be easily developed. The process can befully automated using recursive methodology.

- Test execution without human presence

Tests can be executed 24 hours a day, improving ECU software qualitywhile saving time and costs.

- Perform regulation, security and failure tests without risk

Using HIL simulation, tests can be carried out without harming people orequipment during all stages of a design.

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Introduction - HIL Strenghts (2/2)

- Reduced Time To Market

With HIL simulation, errors can be found early-on and solved early-on. HILsimulation is therefore an effective technique to reduce the commissioningtime.

- Reduced working time for testing

HIL simulation can be a money saver when testing expensive machinery.HIL simulation normally require more work during the early stages ofdesign but save working hours during the testing phase.

- Ensure a high level of robustness and quality

The HIL simulator will grow with the design of the real plant and it revealsproblems and errors that would otherwise have been detected at the finalstages of a design where the control system and plant are integrated.

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HIL setup - TOC

1. Introduction



OBC features

OBC V-Cycle

HIL Strenghts

2. HIL setup

Environment





3. Smart charge

Main standards

PLC ISO 15118

CHADeMo/DC China

4. OBC testing



Traceability

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HIL setup - Environment

Actuators

HIL simulator

Test Automation

Device Under Test

Test Cases

The HIL environment is equipped with the HIL bench, the System Under Test, real actuators, and softwares.It can perform Automatic System Test Validation through execution of Electrical and Functional Test

Test Results

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HIL setup - HW configuration for OBC testing (1/2)

HVDC Power Supply

HVDC Electronic Load

LVDC Electronic Load

LVDC

OUTPUT

HVDC

OUTPUT

HVAC

INPUT

HIL Simluator

External

Interface (I/O, CAN)

Cooling

Ports

L1

N

MAINS

SOURCE

Power Analyzer

Chiller

Actuators

AC Source

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HIL setup - HW configuration for OBC testing (2/2)

HVDC Electronic Loads

HVDC Power Supply


Power Analyzer

HIL Simulator

On Board Charger

Chiller Refrigerator

Main AC Source

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HIL setup - Charging plant model (1/2)

Plant Model

Sensors

simulation

Reaction

measurement

HIL simulator

On Board Charger

C

on

tro

lsig

nals

M

ea

su

red

sig

nals

The product is tested in a Hardware-In-the-Loop bench test which integrate a Plant model which can simulateelectrical physics, dynamics of the vehicle, the charging station and all the vehicle networks (CAN, LIN, PLC)

Charging

Station

Vehicle

NetworksEV Battery

Pack

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Plant Model - Battery


HIL setup - Charging plant model (2/2)

Plant Model – Sensors

Plant Model - Actuators

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HIL setup - OBC real time integration

Battery Simulator


GPIB

Wattmeter

Chiller

SERIAL

ANALOG

HV

DC

and

HV

AC

VH5610 Ethernet

COOLING

PLC

to V

T78

70

TLS

Device Under Test

IO IN

TERFA

CES

Main AC Source

Ethernet Switch

PILO

T and

PR

OX

IMITY

from

VT7

87

0

HVDC and HVAC

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HIL setup - CANoe OBC control panel

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Smart Charge – TOC

1. Introduction



OBC features

OBC V-Cycle

HIL Strenghts

2. HIL setup

Environment





3. Smart charge

Main standards

PLC ISO 15118

CHADeMo/DC China

4. OBC testing



Traceability

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Smart Charge – Main standards

ISO 15118

both AC & DC charging

Plug and charge (PnC)

Power line communication (PLC)

CHAdeMO

Japanese standard

Only DC fast charging

Private CAN bus

GB/T 27930

Chinese standard

Only DC fast charging

Private CAN bus

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PLC

to V

T78

70

TLS

On Board Charger

PR

OX

IMITY

from

VT2

00

4A

Ethernet Switch

PILO

T from

VT7

87

0

VT7870 configured as charging station

(EVSE)

OBC communicates via Control Pilot of

VT7870

VT7870 Ethernet is connected via CAN case

to the Hardware-In-the-Loop system

Proximity line is realized by VT2004A

No power conversion

Operation considering tolerance of main HW

components


Smart Charge – ISO 15118 (PLC)

VT System HIL

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Smart Charge – PLC CANoe panel

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Smart Charge – CHADeMo

System overview

CANoe

CHADeMo

DC China

CONFIDENTIALPag. 24

CANoe Panels – DC Charging with Chademo


Smart Charge – CHADeMo CANoe panel

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Table Of Contents

1. Introduction



OBC features

OBC V-Cycle

HIL Strenghts

2. HIL setup

Environment





3. Smart charge

Main standards

PLC ISO 15118

CHADeMo/DC China

4. OBC testing



Traceability

CONFIDENTIALPag. 26


OBC testing - System test procedure

Technical

SpecificationSystem Requirements

Analysis

System Test

SpecificationVector CANoe

vTEST StudioTest ReportVT System

svn://autospice/PAA00257A-PSA-OBC.DCDC/trunk/91 lh/prod spec/v5.1/00949_15_02061_DCDC_OBC_technical_specification_release_5.1.pdf

svn://autospice/PAA00257A-PSA-OBC.DCDC/trunk/10 dev_wp/04 sys/7.5.1 tech sa con TSC/System Requirements/PAA00257 System Requirements Analysis_v3.0.xlsx

svn://autospice/PAA00257A-PSA-OBC.DCDC/trunk/10 dev_wp/04 sys/8.5.2 item intgr test spec/System test/_draft/PAA00257_System Test Specification_v1.2_draftB.xlsx

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OBC testing - System test tool chain

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OBC testing - Traceability


Rev 2.2

Speaker: Dr. Alessandro Pevere

Main author: Eng. Roberto Moncada

On Board Charger (OBC) Testing for Electric Vehicles (EVs) · On Board Charger (OBC) Testing for...

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