Dynamic AC Emulator Testing charging technology and power electronics efficiently

Transcription

1 Dynamic AC Emulator Testing charging technology and power electronics efficiently

2 Highlights Emulation of global grids The Dynamic AC Emulator (ACE) permits flexible, functional testing of any electrical systems through emulation of global low-voltage grids and possible grid impurities. The ACE offers free configuration of the frequency range, current, voltage, number of phases, phase angles and harmonics for this. Efficient testing of charging technology The ACE can be used in combination with the Scienlab ChargingDiscoverySystem (CDS) to emulate any EV or EVSE. The CDS covers the relevant norms and charging standards (ISO 15118, DIN SPEC 70121, ICE 123 etc.) in this context. Energy-efficient source and sink mode Bi-directionality enables the ACE to be operated as a source or sink. The voltage and current controllers required for this are already implemented and can be parameterized as desired via the customer interface. The ACE is also recuperative, which permits highly efficient and cost-effective operation. Precise and reproducible measurement results The high quality of the measuring and control unit as well as the power electronics in robust EMC design guarantee maximum reliability of use as well as precise and reproducible measurement results. Real-time capable, open interface The ACE offers openly documented interfaces (Ethernet, EtherCAT) as a flexible means of connecting to any automation tools or HiL systems. Powerful FPGAs and microcontrollers ensure a real-time capable interface for time-synchronous control and measurement data evaluation. Modular design The modular design enables up to four 22 kw systems to be connected in parallel. This means that the ACE can also be used to test DUTs with higher power. Retrospective parallel connection is also possible, guaranteeing future-oriented research and development. Additional DC function In addition to the AC function, the ACE also has an additional DC function that can be used to achieve an output voltage of up to 600 V. This means that almost all high-voltage tests in the area of charging technology can be performed with just one device. Dynamic AC Emulator Testing charging technology and power electronics efficiently The major challenge in developing and producing electronic systems is having to comply with different standards worldwide in order to guarantee faultless operation. The steady growth of the electric mobility segment also means an increasing focus on communication between the vehicle and charging infrastructure. The Dynamic AC Emulator (ACE) can emulate both the vehicle and the charging infrastructure, which means that not only the communication but also power flows can be tested under realistic conditions during development. With the ACE as a freely programmable power source and sink, the system can cover all applications in the automotive and industrial fields as an all-in-one system. With this solution, Scienlab offers a flexible and efficient high-end product which is developed and produced at our Bochum site, deploying our long-standing expertise and patented solutions in the field of power electronics. International grids Region Phase Grid voltage Frequency EU 1~ US 1~ Canada 1~ Japan 1~ Africa/Asia 1~ 230 V 400 V (415 V) 120 V 240 V, 480 V 270 V 120 V, 240 V, 480 V 100 V 200 V 127 V, 220 V 380 V 50 Hz 60 Hz 60 Hz 50 Hz / 60 Hz 50 Hz System topology of the Scienlab Dynamic AC Emulator Ethernet/EtherCAT Dynamic AC Emulator DC+, AC supply DC L 1 L 2 L 3 N PE AC Device Under Test (DUT) DC DUT 2

3 Dynamic AC Emulator Fields of application Testing of high-voltage power electronic components and systems that have to undergo comprehensive testing for maximum failure safety, energy efficiency, control and measurement accuracy as well as quality, for example for use in the automotive sector. Bi-directional mode enables electric vehicles (EV) to be emulated as a sink or charging infrastructure (EVSE) as a source in order to analyze their interoperability in combination with the Scienlab ChargingDiscoverySystem (CDS). Validation of AC and DC charging processes by switching over the AC function to the additional DC function. Functional testing of any electrical systems through flexible emulation of global low-voltage grids. Validation of adherence to norms, especially with respect to immunity to interference in the low-voltage grid as well as system perturbation. The right solution for every application Thanks to bi-directionality, integrated AC/DC voltage and current controllers, high dynamics and the energetic recovery system, the Scienlab AC Emulator offers all necessary functionalities for the efficient and effective testing of all power electronic components in EV and EVSE. EV and EVSE emulation Communication between the systems involved in charging plays an important role alongside the power electronics of these charging systems. A successful charging process requires the exchange of information between the charging column and vehicle in order to synchronize the maximum permitted charging power and other limit values of the systems, for example. When combined with the Scienlab ChargingDiscoverySystem (CDS), the ACE is transformed into a comprehensive test environment for the charging interface of all common electric vehicles, wall boxes, ICCB (or IC-CPD) charging cables and charging columns. Details on comprehensive testing of the charging function and interoperability can be found in the Scienlab product brochure for the ChargingDiscoverySystem. Emulation of global grids The ability to emulate global grids is vital when developing electronic devices, automotive components, and machines for international use such as charging columns. It enables the direct validation of the functionality for all target markets and country variants in a laboratory setting. The voltage and frequency must also be within the permitted tolerances for grid quality outlined in the standard IEC If these conditions are met, correct operation of the charging column across the entire tolerance range is ensured. The ACE from Scienlab can be used as a programmable AC power source for emulating global grids. The grid emulation functionality of the ACE with variable voltages and frequencies is designed for one, two and three-phase grids. The fundamental frequency, the voltage for each phase individually as phase-tozero voltage as well as the phase angle for each phase (L1, L2, L3) and the power off thresholds are specified as root mean squares during this process. Asymmetric voltages and phase angles can be adjusted with ease. The power amplifier is completely isolated from the system supply, which means that all grid structures can be modeled. The bi-directionality also enables regenerative devices (e.g. photovoltaic inverters) to be operated and tested in all quadrants. 3

4 Asymmetric voltage specification Representation of harmonic components The ACE can be used to emulate error cases for relevant test requirements and norms as a way of ensuring the CE conformity of systems. When operated as an AC voltage source, tests for the following standards can be carried out: Standards series (excerpt) DIN EN IEC DIN EN IEC Test for interference immunity to voltage changes (over and undervoltage) or failures in one or more phases Specification of amplitude changes with complete phase accuracy via lookup table Test for interference immunity to grid frequency fluctuations The Scienlab ACE can simultaneously generate harmonic components from the 2nd to the 40th harmonic in order to investigate these EMC emissions and immissions. Up to two freely selectable frequencies (interharmonics) with arbitrary frequency (16 2,400 Hz) and individually adjustable amplitude and phase can also be generated and measured. This means that, among other things, the immunity to interference of the DUT can be tested for adherence to the normative specifications. Conversely, all harmonics can be deliberately compensated in order to investigate the DUT's system perturbation with an almost ideal sinusoidal AC voltage (THD < 0.1 %). In this application, tests for the following standards can be carried out: Standards series (excerpt) Frequency range: % of f1 (main frequency) Frequency accuracy: < 0.3 % of f1 Testing for high-frequency interferences Consumer loads involving large, sudden load changes such as furnaces or high-performance rectifiers can cause impurities like harmonics and transients in supply grids. Newly developed devices therefore need to be tested for tolerance to EMC immissions from the interference sources described above. In order to ensure adherence to the given standards, however, electronic components themselves must not exceed a certain level of EMC emissions. DIN EN IEC DIN EN /12 IEC /12 Test for interference immunity to grid distortions Simultaneous control of all harmonics in amplitude and angle up to the 40th order as well as two interharmonics (16...2,400 Hz) Testing of emitted interference and system perturbation Acquisition of the harmonic components in the current up to the 40th order Emulation of a clean grid (THD < 0.1 %) 4 4

5 Dynamic AC Emulator Emulation of active AC and DC sources and sinks To be able to test the output side of AC sources such as charging columns or inverters for operation with different loads, it must be possible to emulate various AC loads. When used as an AC current source, the ACE can also serve as a programmable load in combination with voltages applied externally. The system then enables the current to be specified individually for each phase (one, two and three-phase DUTs possible). Free parameterization of the phase angles makes it possible to specify the type of load and source or sink mode. In the latter case, the energy is fed back directly into the grid, permitting an energy cost reduction. All the parameters required to emulate the load can be changed during operation. In the context of the DC functionality, it is a benefit when testing high-voltage components such as DC/DC converters or chargers to not be restricted by the state of charge, temperature or aging of a real battery. This can be avoided by emulating a highvoltage battery, which also does away with all safety-related risks of an undesired thermal or chemical reaction. When used as a DC voltage source, the ACE from Scienlab can replace any high-voltage battery (e.g. lithium ion) during testing. Freely parameterizable variables such as the open circuit voltage and impedance can be changed manually or via internally or externally calculated battery models at runtime. The high system dynamics mean that voltage drops, for example, can be emulated within milliseconds. Battery models suitable for immediate use can be supplied directly on request. Flexible integration into different test environments The Scienlab Dynamic AC Emulator (ACE) is designed to be used as a standalone test system, in combination with a ChargingDiscoverySystem (CDS) or embedded into a hardwarein-the-loop (HiL) test bench. In the first case, the PC software Emulator Control assists the user with manual control. In the field of charging technology, the ACE is controlled in combination with the CDS via the Scienlab software ChargingDiscover. In the third case, the HiL system can directly access the appropriate parameters and functions via the open interface. Operation via the software Emulator Control The Windows-based PC software Emulator Control is used to manually control individual emulators or a network of emulators in the test bench, for example for operation in the case of grid emulations. The Scienlab software is precisely tailored to the customer applications and the desired test bench functionalities. The user can see all the relevant electrical model parameters at a glance. The data can also be imported and visualized at any time. In addition, the software can be used to administer complete parameter sets and system messages, supports flexibly programmable voltage curves and has an integrated service area. AC mode as current source/sink User interface of the Scienlab software Emulator Control 5

6 Important software functions: Measured value output/scope view Visualization of error and system messages Storage and loading of complete parameter sets and user layouts Operation via the software ChargingDiscover In the field of charging technology, the ACE can be controlled via the ChargingDiscoverySystem (CDS) in combination with the Windows-based ChargingDiscover PC software for communication and performance tests. The CDS tests the functionality and interoperability of all the components involved in the charging process by emulating the charging communication of the EV and EVSE. At the same time, the electrical parameters are measured and checked for compliance with the standards. Test sequences can be defined freely and subsequently performed manually or automatically via the ChargingDiscover PC operating software. The software is used via application-specific user screens that provide the user with all necessary control elements and test parameters according to the selected use case (EV or EVSE test). The software also comprises all necessary functions for the visualization and evaluation of individual messages and measured values as well as for the automatic generation of reports. User interface of the Scienlab software ChargingDiscover Integration into a HiL test environment In addition to designing standalone systems or fully outfitting laboratories, Scienlab also offers hardware-in-the-loop (HiL) test environments. When integrating an ACE into a HiL system, it can be integrated both into existing test benches as well as new test bench designs for various fields of application. The systems are connected with ease to the customer interfaces (e.g. EtherCAT, Ethernet) using openly documented protocols. Over and above the charging process, the ACE can be integrated into a Scienlab Power HiL test environment in order to emulate peripherals such as vehicle electrical systems or a residual bus simulation. Further possible components of such a test environment are the Dynamic DC Emulator (DCE) and the Charging- DiscoverySystem (CDS). Dynamic DC Emulator (DCE): The DCE is used if the application goes beyond simple DC charging. The DCE works both as a DC voltage source and a DC current source and can therefore emulate any sources such as universal DC charging columns with current limitation. It is equipped with a freely programmable battery model, which enables different energy storages or electrical loads in high-voltage DC grids to be emulated. The required DCE configuration can be adapted in terms of voltage, current and power as appropriate to the customer's wishes. With initial values of up to 1,000 V and 1,200 A, the system is optimally designed for the requirements of the automotive sector among others. Charging DiscoverySystem (CDS): The CDS tests the functionality and interoperability of all the components involved in the charging process by emulating the charging communication of the EV and EVSE. At the same time, the electrical parameters are measured and checked for compliance with the standards. Test sequences can be defined freely and subsequently performed manually or automatically via the ChargingDiscover PC operating software. The CDS also assumes synchronized triggering of the power sources and sinks (ACE, DCE) within a HiL test environment. 6

7 Dynamic AC Emulator Integration into a HiL test environment Grid emulation DUT EV/EVSE emulation Dynamic AC Emulator or ChargingDiscovery System Dynamic AC (DC) Emulator HiL (option) Charging Discover Technical data of the Scienlab Dynamic AC Emulator Dynamic AC Emulator AC function DC function Output power Control modes Energy conversion efficiency > 85 % ± 11/22/44 kw (additional power increase possible through parallel connection) Current control, voltage control Output voltage U [1~] rms VAC 600 VDC Output voltage U [] rms VAC - Max. output current I 16, 32, 64 A rms ± 33, 66, 132 A Fundamental frequency Hz - Measuring accuracy U ±0.25 % of measured value ±0.05 % of measuring range ±0.05 % of measured value ±0.01 % of measuring range Measuring accuracy I ±0.25 % of measured value ±0.05 % of measuring range ±0.05 % of measured value ±0.01 % of measuring range Voltage dynamics 10 % 90 % < 1 ms 100 V 200 V < 1 ms Voltage ripple < 300 mv rms < 500 mv rms Impedance < 0.1 ohm per phase - Total harmonic distortion (THD) < 0.1 % (with control using harmonics) - Cycle time Interfaces Dimensions of desktop unit/system cabinet (depth x width x height) Weight 1 ms Ethernet, EtherCAT 600 x 560 x 1100 mm / 800 x 800 x 2630 mm Approx. 100 kg, 22 kw each Texts, photos and graphic designs in these documents are protected by copyright. Use, dissemination or reproduction is permitted only subject to prior agreement by Scienlab electronic systems GmbH. 7

8 P-ACE-1E-1016 Scienlab electronic systems GmbH Lise-Meitner-Allee Bochum Germany phone fax web mail info@scienlab.de