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HIL Tests for Electric Vehicle Supply Equipment

In this use case, the electric vehicle communication controller (EVCC) is simulated to test the electric vehicle supply equipment (EVSE) and its behavior when the equipment is connected to different simulated electric vehicles.

  • Testing real charging stations and communication controllers as well as their behavior when they are connected to different simulated electric vehicles
  • Simulating electric vehicle communication controllers (EVCC) according to CHAdeMO, GB/T, ISO 15118, DIN SPEC 70121, SAE J1772, and IEC 61851-11)
  • Testing various electronic control units and power electronics components involved in the charging process 
  • Support of AC and DC charging 

Task

Involving simulated electric vehicles in the testing process is crucial for validating charging station technologies. This requires a comprehensive test solution taking into account all parameters relevant for electric vehicle charging worldwide.

Challenge

There are many manufacturers for electric vehicles (EV) as well as electric vehicle supply equipment (EVSE). At the same time, charging infrastructures also differ significantly depending on the region. To manage this large variety, the communication between the EV and the EVSE is specified in several standards, such as CHAdeMO, ISO 15118, and GB/T, all of which must be taken into account when testing charging stations for electric vehicles worldwide.

To verify their implementations, EVSE manufacturers can include numerous real electric vehicles in their tests. However, this procedure leads to high testing efforts, while still not guaranteeing full interoperability as parameters might change slightly from electric vehicle to electric vehicle, even if they are from the same manufacturer. To support EVSE manufacturers in their validation processes, dSPACE provides the Smart Charging Solution that simulates the EVs according to customer requirements. 

Solution

For testing charging technologies, the DS5366 Smart Charging Interface from dSPACE is connected to a HIL simulator via CAN FD. For this use case, a SCALEXIO customized rack system is equipped with a SCALEXIO LabBox, a DS6001 Processor Board, a DS6101 Multi-I/O Board, and a DS6341 CAN Board as well as a battery emulation system, safety components, and power electronics, which are typically installed in an electric vehicle. The DS5366 Smart Charging Interface simulates the communication controller of the EV according to ISO/IEC 15118-1, -2, -3, DIN SPEC 70121, SAE J1772, and IEC 61851-11), while the CHAdeMO and GB/T specific communication controllers are simulated on the SCALEXIO LabBox. Using Simulink® models that are included in the Smart Charging Solution from dSPACE, you can simulate different electric vehicle communication controllers and their behavior, including timing and message manipulation. The actual communication between the charging station and the simulated electric vehicle is done via the control pilot (CP). 

1) ISO 15118 and DIN SPEC 70121 communication will be available with a later Release.