Advanced High-Voltage Ripple Testing – Future-Proof with BOLAB Systems

Advanced High-Voltage Ripple Testing – Future-Proof with BOLAB Systems

Next-Generation Ripple Testing for EV & Automotive Components

High-voltage ripple testing is critical in the electric vehicle (EV) industry, ensuring reliability, safety, and compliance with an ever-evolving landscape of standards. With the increasing complexity of power electronics, battery systems, and inverters, ripple disturbances must be tested rigorously to meet ISO 21498-2, ISO 7637-4, LV123, VW 80300, MES PW 67602 (Mazda), Nissan 28400 NDS91, and emerging global standards.

BOLAB Systems' innovative approach to ripple testing sets a new industry standard by offering in series amplifier integration, advanced coupling technology, and the ability to extend beyond sine ripple to perform square, trapezoidal, Pulses, and triangle waveforms making it the most future-ready solution available.

Understanding Ripple & Its Impact

A ripple is a high-frequency disturbance signal superimposed on the DC power supply, often caused by switching operations in semiconductor components like inverters, DC-DC converters, and onboard chargers (OBCs). This can be more than just a sine wave in actual measurements.

These disturbances can have severe effects on electric vehicle (EV) systems, including:

• Battery Management System (BMS) Failures – Ripple coupling at 30 kHz can trigger the battery contactor, leading to complete vehicle shutdown.
• Component Damage – Excessive ripple voltage can destroy input filters of DC-DC converters and inverters, causing costly failures.
• Malfunctions in HV Components – High ripple currents transmitted through the HV network can interfere with sensitive vehicle electronics.

The Challenge – Low Impedance DUTs & High Ripple Currents

HV batteries and inverters present a significant challenge due to their low impedance over the frequency range. This makes them more susceptible to high ripple currents, requiring a high-power ripple generator capable of delivering precise, controlled waveforms.

For example, according to ISO 21498-2, an HV battery with an impedance of 126mΩ at 1,050 Hz requires:

•  Ripple Voltage: 24 Vp
•  Ripple Current: 190.5 Ap (134.7 Arms)

At a resonance frequency of 57,896 Hz, HV inverters have an impedance of just 4.23mΩ, which translates to an enormous 5700 Ap peak current requirement—far beyond what traditional ripple generators can handle.

Figure: Example Impedance Measurement from 10 Hz – 250 kHz in

Figure: Example Impedance Measurement with Current Showing the Dramatic Swing of Current with Just a 2 V Level

To address this, BOLAB Systems has revolutionized ripple testing with a unique coupling method and DAQ integration, ensuring:

•  Easy, fast DUT Impedance Measurement <1min
•  Accurate & Repeatable Test Conditions
•  No saturation of coupling transformer for low frequency (start a test from DC)
•  No loss of voltage through the Transformer because of high impedance at higher frequency
  
•  Protection Against DUT-Induced Failures
  
•  High-power, High-Frequency Test Capabilities

In the example below, the DUT is just being tested with an LV Ripple riding on 5V Signal; this is a low voltage test similar to what is in ISO 16750 2. For HV 400V, 800V, or 1000V, the sweep and results would be the same.  DUT is swept from 10 Hz to 150 kHz. You can see the same two resonance frequencies as above but now on a linear graph.

Figure: Example Measurement with no compensation on Low Voltage System in WaveMaster Software

Figure: Close-up of test, showing High Current and Voltage drop on

Figure: Showing Current limited to 8 amps on AC Ripple, limit is user-selectable

Figure: Showing BOTH AC Voltage Compensation & AC Current limiting to 8 amps on AC Ripple

BOLAB Systems – Advanced Ripple Coupling & Future-Ready Testing

 Unique Series Amplifier Integration with HV Source

BOLAB’s exclusive technology integrates the amplifier in series with the high-voltage source, allowing precise ripple control across a wide frequency range. This direct series coupling ensures:

•  Stable Ripple Injection Without Distortion
•  Higher Test Voltage Range (Up to 1000V DC)
•  No Load Interference from External influences of the coupling method
•  Use any existing HV Supply; just needs a safety interlock
• `Or Pair with our Fastest on-the-market HV Power supply to meet all other Voltage tests

 Beyond Sine Ripple – Square & Trapezoidal Waveform Testing

With new standards like Nissan MES PW 67602, Mazda 28400 NDS91, and evolving OEM specifications, the requirement for square and trapezoidal ripple waveforms is becoming essential.

BOLAB’s ripple test system is one of the first to provide:

•  Custom Waveform Generation (Sine, Square, Trapezoidal, and Arbitrary)
•  Full Compliance with Existing & Future Standards
•  Real-Time DUT Response Monitoring & Automated Test Sequences

Multiple Coupling Methods for Ultimate Flexibility

Unlike traditional ripple test systems, BOLAB’s solution supports:

•  Direct Coupling – For low/high-voltage, high-frequency applications
•  Inductive Coupling (Transformer-Based) – If mandatory by a standard, but the drawbacks limit performance, not recommended

Intelligent DUT Current Limiting for Protection

BOLAB’s system automatically:

•  Detects DUT impedance changes in a
•  All measurements are built into the system’s DAQ
  
•  Adjusts test voltage dynamically to set the current limit on AC Signals
  
•  Prevents excessive ripple currents that could damage components
•  Maintain voltage over frequency; even a short wire has inductance with a higher frequency. The BOLAB system automatically compensates for this drop

 Meeting & Exceeding Global Ripple Testing Standards

BOLAB Systems' high-power ripple generator supports compliance with:

•  ISO 21498-2 – HV component testing for EVs & hybrid vehicles
•  ISO 7637-4 – Electrical transient conduction on shielded HV lines
•  Stellantis CS.00245, FORD FMC1280, Volvo STD 515-0003
•  LV123 & VW 80300 – High-voltage ripple requirements for German automakers
•  Nissan MES PW 67602 & Mazda 28400 NDS91 – Square & trapezoidal ripple testing
•  PSA B21 7110, BMW GS 95023, Renault 36-00-811 – OEM-specific ripple immunity tests

Test Range:

•  Frequency: 10 Hz – 300+ kHz
•  Ripple Voltage: Up to 100 Vpp
•  Ripple Current: 100A Up to 2000A+ (onsite expandable)

BOLAB High-Power Ripple Generator – The Most Advanced Solution

 Fully Integrated System

•  Amplifier & Measurement Device in One Package
•  HV Power Supply Sink/Source (Can use your own, requires interlock)
•  Safety First: Capacitor Banck for decoupling HV Supply from Ripple.
• Active and passive discharge to protect the user from HV shock
• Interlock to shut down HV supply, Amplifier, DUT safely
•  Safest setup available. Ask Why
•  AN Artificial Network called out in many standards
• Provide an ISO calibration under heat/current loading to meet very tight tolerances.
• Capacitor Bank Built into AN to maintain short connections and calibration
• If the Capacitor bank is separate from AN, impedance cannot easily be maintained.

 Real-Time Monitoring & Automation

•  Automated Test Sequences & DUT Behavior Analysis
•  Customizable Waveforms & Data Logging

 Safety & Future-Proofing

•  Interlock System for Operator Protection
•  Upgradable Software to Support New Standards

Why Choose BOLAB Systems for Ripple Testing?

1.  Most Advanced Ripple Testing Solution – Ready for today & the future
2.  High-Power, High-Frequency Testing – Unmatched performance
3.  Seamless Integration with Any Test System – Highly protected from damage
4.  Real-Time DUT Analysis & Impedance Adaptation – Ensures precise testing
5.  Customizable & Scalable – Modular design for evolving needs

Get Ahead of the Curve – Future-Proof Your Ripple Testing

As battery voltages increase, charging speeds accelerate, and OEM ripple requirements evolve, BOLAB Systems ensures that your test setup remains ready for future compliance.

Contact Absolute EMC today for a customized solution tailored to your high-voltage ripple testing needs!