Summary
- 800 V power architecture is the next choice for EVs, requiring components to be more durable
- Hardware-in-the-Loop (HIL) Simulation is used in EV development to test system behavior
- PXI and LXI platforms are recommended for creating a HIL test platform
- Components from 400 V systems can be reused in 800 V architectures with PXI and LXI platforms
- Pickering Interfaces offers products like battery cell simulators for use in 800V architectures
Article
The transition from 400 V to 800 V power architecture for electric vehicles (EVs) requires components to be more durable and suitably rated. However, most test equipment used for 400 V EV system development can be re-used for 800 V by ensuring it can handle higher voltages, making the transition easier for EV developers. Hardware-in-the-Loop (HIL) simulation is a test-driven strategy used in EV development that allows hardware like a Battery Management System (BMS) to interact with a simulated environment mimicking real-world conditions. This enables early identification of design flaws and weaknesses, allowing for timely improvements and cost savings later in development.
Creating a HIL test platform from scratch can be costly and time-consuming, so using an industry-standard platform like PXI or LXI is recommended. These platforms are based on PCI and Ethernet industry standards, respectively, and are supported by global vendors with many commercial off-the-shelf products available. When transitioning from a 400 V to an 800 V architecture, OEMs and system houses can still use many existing modules with PXI or LXI platforms, allowing for significant reuse of the test system. Components that need replacement due to higher voltage ratings can easily be swapped out with upgraded versions due to the modularity and scalability of these platforms.
Cell-level simulation is crucial for EV development, particularly for the accurate recognition of a fully charged battery pack by the BMS. Simulating individual cells and stacking them to achieve the necessary voltage is essential, and the BMS also manages cell balancing, requiring simulation of different cell behaviors. High-voltage switching is another important aspect in test systems for EVs, enabling the connection or disconnection of signals and routing between points. Pickering Interfaces offers various modules for high-voltage switching, such as relays capable of handling high voltages for power switching applications.
Temperature monitoring is essential in EVs, and simulating resistance temperature detectors (RTDs) can help in testing designs across a wide range of temperatures without the need for expensive environmental test chambers. Pickering Interfaces provides PXI-based RTD simulator modules that can simulate different temperature ranges with high resolution. Fault insertion/injection is also crucial in system development and verification, allowing for the safe testing of control systems under various fault conditions. Pickering Interfaces offers fault insertion units designed for safety-critical applications like battery pack testing.
Moving from 400 to 800 V architectures in EVs offers benefits like higher performance and faster charging, but also requires greater durability and safety. Simulation is crucial in verifying the EV’s architecture and systems, enabling easy test conditions and results traceability. Using PXI and LXI-based test equipment provides an easy migration path for manufacturers, optimizing key system components and accelerating system development through automated testing. Overall, utilizing industry-standard platforms and modular test equipment can streamline the transition to 800 V architectures in EV development.
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