On Board Charger (OBC) Testing for Electric Vehicles (EVs) · On Board Charger (OBC) Testing for Electric Vehicles (EVs) Introduction - OBC V-Cycle Calibration Calibration Bench testing
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On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Rev 2.2
Speaker: Dr. Alessandro Pevere
Main author: Eng. Roberto Moncada
CONFIDENTIALPag. 2
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 3
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Introduction - TOC
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
CONFIDENTIALPag. 4
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 5
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 6
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 7
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 8
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 9
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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.
CONFIDENTIALPag. 10
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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.
CONFIDENTIALPag. 11
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
HIL setup - TOC
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
CONFIDENTIALPag. 12
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 13
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 14
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
HIL setup - HW configuration for OBC testing (2/2)
HVDC Electronic Loads
HVDC Power Supply
LVDC Electronic Load
Power Analyzer
HIL Simulator
On Board Charger
Chiller Refrigerator
Main AC Source
CONFIDENTIALPag. 15
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 16
Plant Model - Battery
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
HIL setup - Charging plant model (2/2)
Plant Model – Sensors
Plant Model - Actuators
CONFIDENTIALPag. 17
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
HIL setup - OBC real time integration
Battery Simulator
LVDC Electronic Load
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
CONFIDENTIALPag. 18
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
HIL setup - CANoe OBC control panel
CONFIDENTIALPag. 19
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Smart Charge – TOC
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
CONFIDENTIALPag. 20
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 21
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
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Smart Charge – ISO 15118 (PLC)
VT System HIL
CONFIDENTIALPag. 22
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Smart Charge – PLC CANoe panel
CONFIDENTIALPag. 23
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Smart Charge – CHADeMo
System overview
CANoe
CHADeMo
DC China
CONFIDENTIALPag. 24
CANoe Panels – DC Charging with Chademo
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
Smart Charge – CHADeMo CANoe panel
CONFIDENTIALPag. 25
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
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
CONFIDENTIALPag. 26
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test procedure
Technical
SpecificationSystem Requirements
Analysis
System Test
SpecificationVector CANoe
vTEST StudioTest ReportVT System
CONFIDENTIALPag. 27
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test tool chain
CONFIDENTIALPag. 28
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test tool chain
CONFIDENTIALPag. 29
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test tool chain
CONFIDENTIALPag. 30
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test tool chain
CONFIDENTIALPag. 31
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test tool chain
CONFIDENTIALPag. 32
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - System test tool chain
CONFIDENTIALPag. 33
On Board Charger (OBC) Testing for Electric Vehicles (EVs)
OBC testing - Traceability
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