Chroma ATE introduces the Chroma 8620

OBC and DC-DC Converter Power HIL

Testbed for testing electric vehicle charging

systems and powertrain components.

Hardware configuration can be adapted

according to DUT specifications, with options

including a programmable DC power supply,

programmable DC electronic load, digital

power meter, and oscilloscope. Chroma

8620 can be applied to different system

architectures and boasts expansion and

sharing of the platform.

Chroma 8620 is specially designed for

research and development of on-board

chargers (OBC) or DC-DC converters. Its

flexible software provides user interfaces

for operation and monitoring of manual and

automated test functions and automatically

generates comprehensive test reports.

Users can quickly conduct large numbers of

repeated tests, improving test coverage and

efficiency.

Chroma 8620 supports the loading of Altair

Activate models or Model-Based vehicle

models so that users can continuously apply

existing vehicle models, saving the trouble

and time of redevelopment. Moreover, CAN

HS/FD and LIN communication interfaces are

able to load DBC and LDF communication

files.

For functional testing, Chroma 8620 can

simulate normal operating conditions of the

DUT in a real vehicle environment. It can also

simulate abnormal operating conditions,

including communication abnormalities and

signal faults (Open Circuit, Short to Ground,

Short to Battery, Pin-to-Pin Short). This

serves to avoid possible hazards during the

charging process or when the vehicle is on the

road. Laboratory simulation testing not only

diminishes the risk of accidents in the actual

vehicle, but also eliminates the high costs

associated with using real vehicles for testing.

OBC AND DC-DC CONVERTER

POWER HIL TESTBED

MODEL 8620

KEY FEATURES

■ Supports customized hardware

configuration, platform sharing,

and expansion

■ Flexible software platform

- Easy to operate and monitor user

interfaces

- Manual testing capabilities

- Automated test program editing

- Automated test report generation

- Supports LabVIEW, C/C++, Python,

.NET languages

- Supports data recording

■ Supports CAN, CAN FD,

LIN communication

■ Real-time monitoring for safety testing

with an independent PLC system

■ Supports signal fault injection simulation

(open circuit, short circuit)

■ Supports loading of Altair Activate models

and model-based models

■ Supports UDS diagnostics (ISO 14229)

■ Supports GBT, QCT standards testing

APPLICATIONS

■ OBC calibration & verification

■ DC-DC converter calibration & verification

■ OBC & DC-DC converter 2-in-1

calibration & verification

■ Reliability and durability testing

■ Vehicle driving cycle conditions simulation

■ System integration testing

Preliminary

Chroma 8620 OBC and DC-DC Converter Power HIL Testbed supports the hardware-in-the-loop test from the ISO 26262 V-model for functional

safety in the development of road vehicles. It includes failure mode, functional hazard analysis, and potential risk functions related to the OBC and

DC-DC converter in the design stage of the V-model. Various vehicle conditions can be simulated and tested on the bench. Users can discover and

correct problems early, well before entering real vehicle tests, which helps in obtaining ASIL (Automotive Safety Integrity Level) accreditation. The

testbed allows for the expansion or replacement of peripheral equipment to meet the test requirements of different DUT specifications. Also, by

simply modifying existing programming, users can begin a new test project without starting from scratch. Chroma 8620 allows for highly repetitive

automated tests and reduces possible errors caused by continuous manual programming of test specifications. Not only can this testbed reduce

the number of tests and development costs, it also helps to shorten the test time and improve overall test efficiency.

Chroma 8620 has an independent PLC monitoring system, which can track the running status of the system software and test hardware in real

time. When an error occurs, the protection and warning mechanisms are activated to avoid damage to the equipment and the DUT. The flexible

software platform allows users to load CAN HS/FD and LIN communications files as well as combine real-time systems, power and measurement

equipment, and vehicle models. This provides easy to perform real-time dynamic tests on OBC and DC-DC converters. The user interfaces and

automated test procedures are so flexible they can be edited even during the execution of manual or automated tests. Automated test functions

support upper-level test software using an ASAM XIL interface. After the test procedure is completed, test reports are automatically generated

for convenient review of test changes and results. While testing, the test data can also be recorded and accessed in TDMS, CVS, and Text formats,

for additional analysis.

Both the user interfaces and auto test procedures allow repeated editing or copying into new projects, so users can adapt test plans and apply

them to different DUTs or projects. Additionally, in auto test procedures, users can implement well-known languages such as LabVIEW, C/C++,

Python, and .NET, to increase flexibility, reduce repetitive engineering, and improve overall development efficiency.

VEHICLE DEVELOPMENT PROCESS AND TEST REQUIREMENTS

CAN

GPIB

USB

Ethernet

Ethernet GPIB

FIU USB

CAN LIN

DIO AIO

AC Source 61500 Series

Real-Time System

PLC

System

Tri-color

Signal

Host Unit

IPC

DC Source

62000P, 62000L Series

DC Source 62000H, 62000D Series

DC Load 63200A Series

Regenerative AC Source 61800 Series

Connection Area

(Power Signal)

DUT

(OBC/DC-DC)

Connection Area

(IO Signal/BOB)

Specification Requirement

System Architecture, Vehicle Requirement

System Design

System Function, HARA, DFMEA

System Integration

Component Test

MIL, SIL, Signal HIL, Power HIL

Design

ISO 26262

V & V

• Code Analysis

• Control Flow Test

• Data Test

• Time Test

• Fault Injection Test

• Unable to quickly respond to varying test requirements

• Requires manual test execution

• Unable to reevaluate test schedules, delaying production

• Higher development costs

Traditional

Testing

• Responds to varying test

requirements in real time

• Repeats automated tests

• Shortens test schedules

• Reduces development cost

Chroma 8620

Innovative

Testing

Time

HW/SW Design

HW/SW Function

Sub-Function Design

HW/SW Sub-Function

Sub-Function Test

Unit Test

Vehicle Integration

SW1 Phase A

SW1 Phase B

SW1 Phase C

SW2 Phase A

SW2 Phase B

SW2 Phase C

Time

SW1 Phase A SW1 Phase B SW1 Phase C SW2 Phase A SW2 Phase B SW2 Phase C