Electric Vehicle Inspection Solutions

With the rapid increase in the number of electric vehicles, conducting necessary technical inspections on the electrical safety of these vehicles has become a very practical need. As the country with the largest global ownership and the fastest growth rate of electric vehicles, China has already issued national standards for mandatory electrical safety inspections of electric vehicles. In accordance with these standards, Cosber has developed a corresponding technical solution.


Features:

  • Support EV and PHEV with 2WD & AWD including LDV and HDV;

  • Reliable and trust-able technical test on electrical system and module test;

  • Good ability to simulate the actual dis-charging working mode;

  • Applicable on kinds of mainstream charging port of CCS, GB-AC/DC, ChaDoMo.

PRODUCT ENQUIRY

Details

EV Test Functions

Visual checking

Visual checking Insulation & Equalization Test  Insulation & Equalization Test   BMS Charging Test BMS Charging Test 

Whether below items has any visual damage

Charging Part & Socket;

Instrumentation & Signal Indicators;

Power Battery;

Wiring Harness & High-voltage Components;

DC Charge Insulation;

AC Charge Insulation;

Potential Equalization Between Shell & E Platform;

Potential Equalization Between Shells;


State of Charge;

Max. Temperature of Battery;

Max. Voltage of Secondary Cell;

Charging Simulation for State of Health;


Discharging simulation ECU Dis-charging Test BMS Dis-charging Monitoring  BMS Dis-charging Monitoring   Dis-Charging simulation Dis-Charging Simulation


Real-time monitoring of the performance via EV-OBD

Driving Motor Temperature;

Motor Controller Temperature;

DC/Dc Converter Temperature;

Real-time monitoring of the performance via EV-OBD

Max.Temperature of Battery;

Min.Voltage of Secondary Cell;

Driving at 0~130km/h on the 4WD chassis dyno;

Test the basic stability of driving;
EV Electromagnetic radiation Test;



Background

According to the requirements of China's National New Energy Vehicle Development Plan(2021-2035), Electric Vehicle becomes the main part of Automobile industry. To ensure on-road safety, charging safety, and driver safety with electric vehicles, in-use electric vehicles should be tested and evaluated using effective and pragmatic methods.


Electric Vehicle Inspection Solutions


Video: The Process of EV Test Solution



Test Process


The solution encompasses two core parts: charging detection and discharging detection. Charging detection, also referred to as static detection, primarily assesses the performance of potential equalization and the insulation resistance of the charging port. Discharging detection, known as dynamic detection, mainly evaluates the safety of the power battery, the drive motor, and the electronic control system.


Electric Vehicle Inspection Solutions


SL
 Test Item
 Value Standard Result
Test ltem : Power Battery Safety
1 Charging Max. Temperature of 8 attery 31 ≤60℃ PASS
2 Max, Voltage of Secondary Cell 374 ≤4.5V PASS
3 Secondary CellValtage Range 000
 ≤0.3V PASS
4 Discharging Max.Temperature of Battery 31 ≤65℃
 PASS
5 Min.Voltage of Secondary Cel 352 >1.8V PASS
Test Item：Driving Motor Safety
6 Driving Motor Temperature 600
 ≤175℃ PASS
7 Motor Controller Temperature 550 ≤95℃ PASS
Test Item：Electrical Control System Safety
8
 DC/DC Converter Temperature 400
 ≤95℃ PASS
Test Item :Electrical Safety
9 DC Charge Insulation 4515014.6 ≥100Ω/V PASS
10 AC Charge Insulation 1096.5 ≥1MQΩ PASS
11 Poterntial Equalization Between Shell&E Platform 0.07 ≤0.10Ω PASS
12 PentialEqualization Between Shells 0.02 ≤0.20Ω PASS
Remark：This is the screen shot of actual test report based on China technical regulation, and it shall be different case by case due to the different regulation and technical condition.

Core Configuration

EV-OBD


EV Charging Safety Tester(CCS-2 type)

Introducing the Cosber’s EV Charging Safety Tester, designed for electric vehicles with European CCS-2 charging standards. This advanced equipment offers comprehensive testing and monitoring capabilities, including high voltage insulation checks, potential equalization assessments, and BMS communication analysis. Additionally, it functions as an AC/DC EV charger, providing versatility and convenience in one device.


EV Charging Safety Tester(CCS-2 type)


Detection Function

Test Function Value Range Standard
SOH 0-100% ≥70%
DC Charge Insulation 0-2000KΩ/V ≥100Ω/V
AC Charge Insulation 0.1-1000MΩ ≥1MΩ
Potential Equal. btw. EV and P.E 0.01-20Ω ≤0.1Ω
CCS-2 type DC charging capacity 0-30kW

Equipment Parameter

Operational Power
AC 380V+10%，50/60HZ+5%
No-Load/Full Load Power Consumption 0.2/30kW
Operational Environment Temperature:0~40?°C;Humidity:20~90%RH
Dimension(WLH) 600×600×1600mm
Equipment Weight 150Kg

Dynamometer for EV

Dynamometer for EV Dynamometer for EV
Dynamometer for EV Dynamometer for EV


1.Z-Shaft interlinked chassis Dynamometer design for all of motion mode of Ey;


2. Real timmesynchronisation of4 wheels Drive mode avoidingthe Eletronic
Torque Control interference;

3. Automatic wheelbase adjustment mechanism for all of Light EV
(rang:2300-3300mm);



1. Ultra-heavy-duty dynamometer design, with a maximumabsorption power of
1050 kW;

2. Dualdrive shaft roller design, compatible with all types ofheavy-duty vehicles;

3. High dynamic balance dynamometer design, covering speedtests from 0 to
130 km/h;


Dyno Bench Technical Data

Item 4WD EV Dyno(Z-Shaft Linked) Heavy-duty chassis Dyno
Maximum carrying vehicle mass 5000kg -
Maximum bearing axle mass 3000kg 13000kg
Maximum absorption driving force 0〜6000N×2 0-10000 N
Max. test speed 130 km/h 130 km/h
Roller diamete Ф216mm Ф373mm
Roller length 1000mm 1050mm
Inside wheel thread 700mm 900mm
Outer wheel thread 2700mm 2900mm
Minimum vehicle wheelbase 2300mm -
Maximum vehicle wheelbase 3300mm -
Eddy current rated power 160 kw x 2 700 kW(max absorbtion power)
Back drag motor power 7.5kW 11 kw(transducer control)

Software UI

Dis-charging/Charging Test Software Dis-charging Test Interface
Dis-charging/Charging Test Software Dis-charging Test Interface
Charging Test Interface EV Test Operation Info. System
Charging Test Interface EV Test Operation Info. System

General Q&A


 

Q: Is the OBD device available for any EV mode?
  A: No, OBD is based on whether the OBD protocol of the EV, and without it, OBD can not be programmed and used.  

  Q: What is the use of the OBD?
  A: It is used to read the data from the MCU&ECU via OBD port during the dis-charging test.  

  Q: Why the dynamometer is necessary in the solution?
  A: To do the dis-charging test, it is important to make the actual driving simulation.

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