Testing Real Charging Processes

In this use case, the Smart Charging Station Emulator from dSPACE is used to simulate freely configurable charging stations in full and to charge real electric vehicles at DC voltages of more than 1,000 V.

  • AC and DC charging for real electric vehicles
  • DC charging at voltages of more than 1,000 V
  • Carrying out complex field tests in the laboratory with the Smart Charging Station Emulator from dSPACE
  • Simulating freely configurable charging stations in full, including grid emulation option 

Task

When carrying out release tests for new electric vehicles or their individual components, manufacturers must consider the different charging stations in the respective target market. The vehicles and their onboard chargers must be able to deal with a wide range of conditions, including AC and DC charging at different voltage levels, regionally different charging communication standards, and potential failures that might occur during the charging process. This requires a flexible test system with comprehensive parameterization options.

Challenge

The communication between electric vehicles and the charging infrastructure is a key factor for reliable electromobility. To ensure failsafe and robust charging processes, manufacturers need to consider a variety of technological standards, protocols, and even potential sources of error. But testing against many different charging stations in different regions of the world drives up costs and slows down development. In the end, manufacturers still have no guarantee of full interoperability between the various charging stations and the electric vehicles because there are simply too many variations due to hardware dependencies, software versions, and even misinterpreted standards. Test systems with flexible parameterization options make it possible to manage this diversity from the field in a laboratory.

Solution

To test real electric vehicles and onboard chargers, dSPACE offers a special configuration of the SCALEXIO customized system: the Smart Charging Station Emulator. This emulator allows for the full simulation of freely configurable charging stations to carry out complex field tests for onboard chargers and electric vehicles in the laboratory. A special feature of the emulator is its ability to charge real electric vehicles at DC voltages of up to 1,000 V. In customer projects, the configuration can be expanded to include more or bigger power supplies and reach higher voltage or power levels.

In this use case, a real electric vehicle is charged using the Smart Charging Station Emulator, which supports AC and DC charging and all common charging communication standards, such as ISO 15118, DIN SPEC 70121, IEC 61851-1, CHAdeMO, GB/T, and ChaoJi. Using the software, which is provided together with the emulator, the charging station can be configured as required and the charging process can be initiated. While charging, different charging station behaviors can be simulated and error, failure, and malfunction tests can be performed.

The Smart Charging Station Emulator is equipped with the Smart Charging Solution from dSPACE, a SCALEXIO real-time system (SCALEXIO LabBox), as well as power electronics, monitoring devices, and safety components, which are typically installed in a real charging station. The software of the Smart Charging Station Emulator is based on the Smart Charging Interface Software, which includes a Simulink® model and various predefined ControlDesk layouts for overview and configuration purposes.

In this way, our test system helps to accelerate the development process of failsafe high-voltage charging components while reducing development costs and ensuring robust and failsafe charging processes.

Conformance Tests

To ensure interoperability between electric vehicles and charging stations, a considerable number of charging-standard-specific tests has to be implemented and executed. The Smart Charging ISO 15118-4 Conformance Test Suite provides standardized conformance tests for this purpose. Learn how to carry out these tests with our dSPACE solutions.

Basic Information

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