VW 80300 / LV 123: Electric Vehicle Test Systems

World´s most powerful, modular, compact, mobile, and flexible solution for High Voltage testing for Electrical Vehicles!

• LV 123
• VW 80300
• VW 80303
• MBN LV 123
• Porsche VW 80303
• PSA B21 7112
• ETC.

General

 BOLAB´s new and world´s unique solutions in testing High Voltage profiles for Electric Vehicles are very powerful, flexible, and modular.

 Three different solutions for high-speed testing, a medium-range for covering most profiles, and a low budget. Powerful solutions for starting and gaining experience are available.

LV 123 / VW 80300

2014 / 2016 / …

Modular Design 

Modularity is one of the most important characteristics of BOLAB´s systems. Start with a “small” system of 15 KW (1.000 V, 15 A,3U) and expand the module by module as applications require and budgets allow.

It was never this easy to get involved with high voltage tests for Electric Vehicles and to build up these tests to a most powerful solution.

Flexible 

An unmatched and exceptional feature is the flexibility of BOLAB´s systems. The medium and high-end systems can be used equally for all kinds of standards, such as LV 124, VW80000, LV 148, VDA 320 in the same way as OEM standards.

For example, BOLAB’s systems are designed to test DC/DC converters on both sides of low- and high voltage applications.

Powerful 

Wide ranges of power requirements are covered by the BOLAB systems.

15 kW to 200 kW Systems with voltages up to 1.000 V and currents from 15 A to more than 400 A are available

Compact and Mobile 

There is no other complete high-end mobile test solution for Electric Vehicles for VW80000 with 15 kW (1.000 V / 15 A) in a small 19” rack with 10 U height on the market

 BOLAB systems also cover voltage profiles for LV 124 / LV 148 / VW80000 / VDA 320 and OEM standards up to 40A!

High Speed 

Even Load Dump pulses are covered with BOLAB´s, unique in the world, high-end test systems for Electric Vehicles. 

3000 V/ms for 20 V is required in VW80300 with a 7µs rising time.

BOLAB´s solution: better than 1µs!

250 V/ms increase for 150 V: 

	+		=
HV supply		High Frequency 4 Quadernt Supply		Combination in series

WaveMaster

BOLAB´s WaveMaster Software includes all kinds of Library standards such as LV 123, VW80300, VW80303, as well as OEM standards from MBN LV123, PSA Peugeot – Citroen, Porsche, etc.

Everyone can edit easily these standards. But this is not all: new and individual waveforms can also be generated in tabular or/and in graphic spreadsheets. Sine, triangle, rectangle, and other possibilities allow user-defined waveforms generation instantly.

The simplicity of how fast vehicle-captured oscilloscope data signals can be imported is exceptional. Reading ASCII and TDMS data files is also possible the same way. 

BOLAB´s WaveMaster solution is not only gene-rating voltage profiles, it´s also a data acquisition instrument at the same time.

Both live voltage and current measurements with graphic displays, recording and storing data in time to the hard disc for voltage and current to TDMS files are included

Coupling Network Transformers (CDN)

Setup 

For voltage ripple tests on HV batterie lines, there is an easy and economical solution. We use standard HV power supplies. Our 4 quadrant amplifier system 110-75N-TS generates powerful

sine interferences. The BOLAB coupling transformer 450-100 (100 A) allows for high-frequency sine signals.

The BOLAB measurement unit 480-WM measures the AC amplitude that is provided directly to an analog input of the BOLAB 4 quadrant amplifier. BOLAB´s WaveMaster software compares reference signals with measured signals and adjusts automatically the amplitude to meet the automotive standards requirement.

Please note that only one sine wave interferences are possible. Load Dump transients are not feasible

High voltage system setup with coupling network

High Voltage DC Power Supply + 4 Quadrant Amplifier In Series

Setup

As coupling network transformers (CDN) are limited in speed, frequency ranges, amplitude and especially allow only sine interferences, this solution cannot be used for Load Dump applications. Load Dump requirements are both part of LV 123 and VW 80300 standards.

Our most flexible solution is the combination of a high voltage power supply in series to our 4 quadrant amplifiers. Individual transients and even Load Dump requirements are possible.

In addition, BOLAB’s modular design allows the adaption to almost all manufacturers of high voltage power supplies. There is no need to purchase an additional power supply if one is already available.

System Configuration for Coupling Network/Transformer (CDN)

Parallel mode for high current 

Coupling transformers can be put in parallel to obtain higher currents. E.g. 4 x 450-100 in parallel will allow tests up to 400 A. 

Every coupling transformer needs one 100-75N Amplifier.

4 Quadrant Amplifiers 

• 110-75N                4 Quadrant Amplifier ±75 Vpeak, 40 Apeak, 1.000 W
• 110-75N-TS           4 Quadrant Amplifier ±75 Vpeak, 40 Apeak, 1.000 W incl. WaveMaster Software for Waveform- generation 

Coupling transformers 

• 450-50                     Coupling transformer 50 A
• 450-100                   Coupling transformer 100 A

System Configuration for 4 Quadrant Amplifier in Series

VW 80300 EHV-10 Load Dump with a rapid rate of change	VW 80300 EHV-10 Load Dump all the way to HV voltage limit

Unlimited Waveform Memory 

c::: This technology enables an endless, continuous data stream to the amplifier.

c::: Compared to a function generator with its limited arbitrary memory there is no limitation of the size of the waveform.

c::: A waveform with small spikes and interruptions of e.g. 100 µs and long constant levels in between can be simulated easily.

Variable Waveform Generation

Easy Definition Of Variations 

Meanwhile, many car manufacturers extend the standard waveforms with many variable parameters in time and amplitude.

BOLAB´s comprehensive WaveMaster Software allows doing these variations easily.