On-Board Power System Charging Test Adapter
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Solution Overview
Problem
Current methods for testing the charging process of electric vehicles require driving the vehicle until the battery is empty, leading to significant development effort and loss of testing time, especially for vehicles with a range of approximately 500 km, as charging can only be tested on an empty traction battery.
Innovation Solution
A method and system that allows for the testing of the charging process by feeding electric power into the vehicle's on-board power system and immediately discharging it through an adapter, without storing it in the power storage device, using a defined charging power rate that mimics real charging conditions, allowing for the simulation of a charging process without fully charging the battery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the vehicle is driven to discharge the traction battery after charging, then the charging process can be tested, but the testing time increases significantly
Solution Approach 1:
A power consumption device is introduced as an intermediary component to simulate the battery's power storage function during charging tests. This device directly consumes the charging power on-board the vehicle, eliminating the need to charge the actual battery and subsequently drive the vehicle to discharge it. The intermediary device enables charging process testing to be completed in-situ without the time-consuming charge-discharge cycle.
2Reliability
If the vehicle is driven to discharge the traction battery, then the charging process can be tested, but the development effort increases
Solution Approach 1:
The power consumption device serves as a test auxiliary device that simplifies the testing procedure. Instead of requiring coordinated charge-discharge operations and driver instructions, the intermediary device enables straightforward on-board charging tests, thereby reducing development effort while maintaining testing reliability.
3Reliability
If the vehicle is driven to discharge the traction battery, then the charging process can be tested, but the number of prototypes increases
Solution Approach 1:
The power consumption device enables charging process testing to be performed on a single prototype without requiring multiple vehicles for sequential charge-discharge cycles. This intermediary solution consolidates testing capabilities into one vehicle, thereby reducing the required number of prototypes.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the development effort and testing time by eliminating the need for a driver to drain the battery, enabling faster and more efficient testing of the charging process, and reducing the number of prototypes required, while ensuring that the on-board power system and connected components are subjected to real charging conditions.
Implementation Method 1
electric power used for testing the charging process from the charging station via the charge connection is conducted, e.g. introduced or fed, to and/or into the on-board power system is discharged or removed again via the discharge connection of the adapter
Data Source
AI summary
A method for testing a charging process of an electrically powered motor vehicle having an on-board power system, wherein said on-board power system includes at least one charge connection for connecting the on-board power system to a charging station and is connected to at least one electric power storage device, wherein an adapter having at least one discharge connection is additionally connected to the on-board power system for testing the charging process, wherein electric power for testing the charging process is conducted via the at least one charge connection into the on-board power system, wherein a primary portion of said electric power is discharged again from the on-board power system via the at least one discharge connection of the adapter.