The global electric vehicle (EV) market’s rapid expansion is fueling a critical need for efficient and reliable power conversion systems. Among these, the on-board charger (OBC) plays a vital role, converting AC power from various charging sources into DC power suitable for vehicle batteries. The performance and safety of OBCs directly influence vehicle efficiency, battery longevity, and the overall user experience.
Evolving Demands in EV Power Electronics Testing
As the EV ecosystem embraces advanced features like vehicle-to-grid (V2G) and vehicle-to-home (V2H) capabilities, and as power electronics become more modular and integrated, testing and validation requirements have become significantly more complex. This is especially true under dynamic and variable electrical conditions. Kikusui’s power testing solutions, including the PCR-WEA/WEA2 series of programmable AC/DC power supplies, the PXB series of bidirectional DC power supplies, and the PLZ-5WH2 series of high-speed DC electronic loads, are designed to address these challenges. These tools facilitate detailed evaluation, functional testing, and seamless system integration for OBCs and other critical EV power components like traction batteries, supporting robust characterization for next-generation electric mobility systems.
AC-Side Evaluation for On-Board Chargers
On-board chargers are the primary interface between the power grid and a vehicle’s high-voltage battery, ensuring safe AC-to-DC conversion under diverse input conditions. Modern OBCs are increasingly required to support bidirectional energy flow for V2G/V2H applications, alongside efficient unidirectional charging. Simultaneously, automotive manufacturers are consolidating power electronic components into compact, integrated units to save space, weight, and cost. This trend amplifies the need for:
- Robust AC-side resilience against voltage sags, frequency variations, momentary interruptions, and harmonic distortion.
- Stable DC-side control to ensure proper charging, battery protection, and adherence to global standards.
- Test equipment capable of replicating worldwide grid conditions for repeatable and accelerated development.
Kikusui’s laboratory-grade power systems offer a controlled environment to verify OBCs and battery systems under real-world electrical variability with high fidelity.
PCR-WEA/WEA2 Series: Versatile AC/DC Power Supply
The PCR-WEA/WEA2 Series is engineered for high-capacity, high-precision grid simulation. It supports major global AC configurations for EV charging, including single-phase 120 V (USA), single-phase 200 V three-wire systems, and three-phase 208V for commercial applications. A single unit can replicate these conditions without additional hardware, simplifying testing for global compliance.
The PCR-WEA2 lineup offers AC/DC output ranging from 1 kVA to 36 kVA, with variable single- and three-phase output from 6 kVA upwards. Key features include:
- Output frequency flexibility up to 5 kHz.
- 4x rated peak current capability.
- 1.4x inrush current tolerance for 500 ms.
These capabilities enable engineers to accurately assess OBC performance during startup, simulate grid disturbances, and validate transient handling.
The series includes 1 kVA to 24 kVA models for single-phase applications, expandable via parallel operation up to 96 kVA. Three-phase models range from 3 kVA to 36 kVA, expandable up to 144 kVA.
Sequence Functions for Advanced AC Simulation
The PCR-WEA/WEA2 Series features sophisticated waveform programming to precisely replicate complex utility grid behavior, crucial for evaluating OBC reliability, EMC performance, and compliance with international standards. These sequence functions enable the simulation of:
- Power Disturbances: Undervoltage/overvoltage, voltage dips, swells, fluctuations, instantaneous interruptions, and waveform distortion to test OBC operation during unstable grid conditions.
- Harmonic and Phase Control: Harmonic synthesis up to the 40th order for detailed analysis of power factor correction (PFC) and EMI performance. Adjustable initial phase settings allow for worst-case startup scenario testing.
- Compliance and Standards Testing: Support for major global power quality standards, including IEC 61000-4-11 (voltage variations), IEC 61000-4-28 (frequency variations), and IEC 61000-4-34 (voltage disturbances for high-current equipment).
DC-Side Evaluation for On-Board Chargers
Complementing AC-side testing, Kikusui offers powerful DC-side instruments: the PXB Series bidirectional DC power supply and the PLZ-5WH2 Series high-speed DC electronic load.
PXB Series: Bidirectional High-Capacity DC Power Supply
The PXB Series enables bidirectional operation, allowing for both power sourcing and sinking. This regenerative capability significantly reduces energy consumption during extended test cycles. Supporting voltages up to 1,500 V, it is ideal for evaluating high-voltage battery systems (typically 300–750 VDC) by simulating both charging and discharging conditions.
PLZ-5WH2 Series: High-Speed DC Electronic Load
The PLZ-5WH2 Series provides high-speed transient response and precise dynamic load control. This allows for accurate measurement of OBC output characteristics, such as voltage regulation and transient response. With voltage handling up to 1,000 V, it enables engineers to evaluate OBC behavior under sudden load changes, ensuring safety and reliability.
Integrated System for Comprehensive Testing
By integrating the PCR-WEA/WEA2, PXB, and PLZ-5WH2 systems, Kikusui provides a comprehensive OBC test environment capable of precisely simulating both grid-side and battery-side conditions. This integrated platform supports:
- End-to-end AC-DC performance testing under variable grid conditions.
- Long-term endurance and efficiency testing through regenerative power flow.
- Harmonic, transient, and compliance testing against global standards.
- Optimized energy usage via power regeneration.
This setup ensures thorough validation and accelerated development for next-generation OBC and EV power systems.
Conclusion
As EV power electronics become more sophisticated, the demand for high-precision, globally representative test environments intensifies. Kikusui’s PCR-WEA/WEA2, PXB, and PLZ-5WH2 series offer a complete solution for the AC and DC evaluation of OBCs, high-voltage battery systems, and related power electronics. By providing advanced harmonic simulation, regenerative operation, fast transient control, and compliance-focused sequence functions, these instruments empower engineers to confidently design, validate, and integrate next-generation EV charging and energy management systems.
To learn more, please visit:
- KIKUSUI ELECTRONICS CORP.
- Kikusui America, Inc
- The Benefits of the PCR-WEA Series of AC Programmable Power Supplies – White Paper
- On-Board Charger (OBC) Evaluation – KIKUSUI AMERICA, INC.
- Intelligent Power Supplies: The Benefits of Synchronization and Accurate Power Simulation – White Paper