Kikusui’s cutting-edge power testing solutions for battery, power electronics and on-board charger applications

The rapid expansion of the electric vehicle (EV) sector has intensified the need for advanced power conversion systems that deliver both efficiency and reliability. Central to this is the on-board charger (OBC), which converts alternating current (AC) from various charging sources into direct current (DC) for high-voltage battery systems. As EV technology advances to include features such as vehicle-to-grid (V2G) and vehicle-to-home (V2H) capabilities, testing and validation of these components have become increasingly complex. Kikusui addresses these challenges with its latest power testing solutions, designed to rigorously evaluate OBCs and other critical EV power electronics under diverse and dynamic electrical conditions. Kikusui’s PCR-WEA/WEA2 series of programmable AC/DC power supplies, alongside the PXB bidirectional DC power supplies and PLZ-5WH2 high-speed DC electronic loads, provide a comprehensive testing environment. These systems simulate a wide range of real-world grid conditions, including voltage sags, frequency variations, and harmonic distortions, enabling thorough functional testing and system integration of OBCs and traction batteries. The PCR-WEA/WEA2 series is notable for its ability to replicate global AC configurations—from single-phase 120 V common in the US to three-phase 208 V used in commercial settings—without additional hardware, streamlining compliance testing across markets. The PCR-WEA/WEA2 units feature high power density and advanced transient handling capabilities, including tolerance for inrush currents and peak loads, which are critical for assessing OBC performance during startup and rapid load changes. Their regenerative mode reduces power consumption, while parallel operation allows scalable testing up to 144 kVA, accommodating a broad spectrum of development needs. Additionally, the series offers sophisticated waveform programming to simulate complex grid disturbances such as voltage dips, swells, instantaneous interruptions, and harmonic distortions up to the 40th order, ensuring OBCs can withstand real-world electrical anomalies. These testing capabilities are vital as automotive manufacturers increasingly integrate compact, modular power electronics that combine OBCs, DC/DC converters, and junction boxes. Ensuring stable DC-side control and robust AC-side resilience underpins battery safety, charging efficiency, and regulatory compliance. Kikusui’s solutions thus play a crucial role in accelerating the development and validation of next-generation EV power systems, supporting the transition to more versatile and grid-interactive electric mobility. Looking ahead, the adoption of such advanced testing platforms will likely become standard practice within the EV industry, as manufacturers seek to meet stringent global standards and enhance vehicle functionality. Kikusui’s tools not only facilitate rigorous validation but also contribute to optimising design and performance, helping to future-proof electric vehicle technologies amid evolving grid infrastructures and user demands.