When developing vehicle components and integrating them into the vehicle, a large number of electronic testing and verification systems are required. The development and manufacture of electric and hybrid vehicles place particularly high and diverse demands on test systems and components. As is the case when handling complex control units, the safe measuring, testing, verifying and applying in the high-voltage range require transparent and reproducible test procedures.
In an ideal case scenario, tests and verifications should take place automatically, sequences and test results must be able to be documented automatically for proof of performance and certification. All this requires not only highly reliable and automatable test systems, but also simulations suitable for complex control units – for example to simulate real battery cells – and HV-compatible accessories, such as special cables, break-out boxes and adaptations.
For your high-voltage applications, we design and develop individual adapters, supply systems as well as measurement and simulation technology – for safe handling in the laboratory, on the test bench and on the vehicle (up to 1000 V / 1000 A).
Are suitable for safe and reliable measurements on closed high-voltage systems. Alongside interfaces for tapping individual I/O signals, HV measuring adapters also provide possible access to the HV power supply.
For testing and validating safety-relevant system functions, either during the engineering process or also after repairs carried out by after-sales service or the repair shop, or directly on the vehicle. This enables the testing and verification of correct system responses in a (safety-critical) fault case.
Are used to replace the DC link capacity in the vehicle - and thus simulate one of the most important energy storage devices of the power electronic vehicle system.
Allow the control unit test without real cells. Passive cell simulations simulate the complete cell stack in a balanced state of charge, the individual cell controllers detect suitably charged cells and thus a fully functional battery system.
In order to ensure the highest safety standards for the persons testing and the operating personnel, high-voltage components can be constructed so that they are safe to touch using the complex test adapters. Softing realizes test adapters for high-voltage control units, in other words for Battery Management Controllers (BMC) as well as for Cell Supervision Electronics (CSE).
Specially designed high-voltage charge changeover switches use a special liquid to cool the high-voltage components (charging plugs and charging cables), which are exposed to very high thermal loads at the High Power Charging.
Customized, individual high-voltage supply systems for testing battery management systems and high-voltage components with integrated energy recovery in order not to convert many useless kilowatts of electrical power into heat loss.
Individual high-voltage test setups for the development of electric and hybrid vehicles for the testing and protecting Cell Supervision Electronics (CSE), Battery Management Systems and On-board Chargers, which is coverting mains alternating current (AC) to direct current (DC) while filling up.