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HIL Tests for Onboard Chargers

Testing onboard chargers of electric vehicles with simulated charging stations

In this use case, the electric vehicle supply equipment (EVSE) is simulated to test onboard chargers of electric vehicles and their behavior when connected to different simulated charging stations.

There is a large number of 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 diversity, 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 onboard chargers for electric vehicles worldwide. 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 power electronics and safety components, which are typically installed in a charging station. The DS5366 Smart Charging Interface simulates the communication controller of the EVSE according to ISO/IEC 15118-1, -2, -3, DIN SPEC 70121, SAE J1772, and IEC 61851-1. Using Simulink® models, which are included in the Smart Charging Solution from dSPACE, you can simulate different charging stations and their behavior, including timing and message manipulation. The actual communication between the electric vehicle and the simulated charging station is done via the control pilot (CP).  

Application Areas

  • Testing real electric vehicles and onboard chargers as well as their behavior when connected to different simulated charging stations
  • Testing various electronic control units and power electronics components involved in the charging process  

Key Benefits

  • Simulation of EVSE communication controllers according to ISO 15118 and DIN SPEC 70121
  • Support of AC and DC charging
  • Simulating the behavior of charging stations using Simulink models
  • Logging protocol and status information using USB log and Ethernet raw data