On-Board Charger (OBC) Evaluation

The role of an On-board charger in EVs

An onboard charger is an in-vehicle electrical device that converts alternating current (AC) from a household outlet into direct current (DC) to charge an EV battery pack. In recent years, on-board chargers have become V2H-compatible, which can be used as a power source during disaster situations or in a situation additional power is needed, and there are also modularized types that are integrated with a junction box.

The on-board charger is required to operate normally even in a situation such undervoltage, voltage distortion, momentary breakdown, momentary low, or voltage fluctuation occurs on the AC side, as well as to supply stable power to the DC side and to be tolerant to voltage and current variations of other in-vehicle electrical components.

The role of an On-board charger in EVs
On-board charger AC/DC

AC side evaluation of on-board charger

AC side evaluation of on-board charger The PCR-WEA/WEA2 series of high-capacity smart AC and DC regulated power supplies can be used to evaluate the AC side of on-board chargers. There are several AC specifications for on-board chargers: single-phase 100 V, single-phase three-wire 200 V, and three-phase 200 V, and power of 7 kVA, 11 kVA, and 22 kVA, but the PCR-WEA/WEA2 series can handle all of these with a single unit.

The PCR-WEA/WEA2 series is ultra-compact at approximately one-sixth the size of conventional models, so a single unit can output up to 36 kVA, and the frequency can be varied up to 5 kHz, making it possible to reproduce power supply conditions in countries around the world. It is also highly resistant to inrush currents, capable of delivering peak currents up to 4 times the rated value and inrush currents up to 500 ms, or 1.4 times the rated value.

PCR-WEA/WEA2 Series
Pure sine wave, normal charge simulation

● Various outputs: Single-phase 100 V/200 V, single-phase three-wire, and three-phase 200 V can be output with a single unit.
● Ultra-compact: Up to 36 kVA output in a single unit
● High resistance to inrush current: Peak current rating up to 4 times, inrush current rating up to 1.4 times (500ms)
● Sequence function: Enables power supply voltage fluctuation, output start phase setting, harmonic synthesis, etc.
● Proven track record with all Japan domestic manufacturers
● The power supply situation can be reproduced or simulate in various countries around the world.

Various Sequence Functions

The PCR-WEA/WEA2 series has a variety of sequencing functions and can reproduce undervoltage, voltage distortion, instantaneous breakdowns and instantaneous lows, and voltage fluctuations that occur on the AC side, as well as create harmonic composite waveforms up to 40th order.

Using the PCR-WEA/WEA2, users could create a situation for example the phase at the start of output can also be set so that input waveforms with phases of 90 or 270 degrees, which are severe for on-board chargers. In addition, tests can be performed in accordance with international standards for power supply regulation, such as IEC61000-4-11, IEC61000-4-28, and IEC61000-4-34.

Power Line Disturbance Immunity Testing Software
Various Sequence FunctionsPCR-WEA/WEA2
DC side evaluation of on-board charger

DC side evaluation of on-board charger

For the DC side of the on-board charger, the PXB series bidirectional high-capacity DC power supply or the PLZ-5WH2 series DC electronic load device can be used.

For aging evaluation, etc., we recommend to use the PXB series as it significantly reduces power consumption. The PLZ-5WH2 series is also ideal for acquiring transient electrical characteristics data of on-board chargers. On-board chargers are often connected to high-voltage batteries, which are typically 300 to 750 VDC, but the PXB series and PLZ-5WH2 series can handle voltages up to 1500 and 1000 V, respectively.

obc figPCR-WEA/WEA2PLZ-5WH2PXB

● For aging tests, we are also recommend the PXB series, which regenerates power because it provides significant power savings.
● We recommend using PLZ-5WH2 series when measuring transient characteristics, since the PLZ-5WH2 series equipped with fast transient function.
● The PXB series can handle a maximum voltage of 1500 V and power of 200 kW or more, while the PLZ-5WH2 series can handle high voltage and large capacity of 1000 V/100 kW.
● Onboard chargers are often connected to high-voltage batteries, with voltages typically ranging from 300 to 750 VDC.

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