Shenzhen CPET Electronics Co., Ltd.

The core component of the inverter aging test equipment 5

五,Safety and Protection Unit (System Operation Assurance) Comprehensively ensure the safety of testing equipment, the tested products, the operators and the power grid. ●  Electrical safety:The system is equipped with overvoltage, overcurrent, short circuit, leakage current, reverse connection prevention, and rapid fuse protection devices. ●  Emergency control:Install an emergency stop button to enable rapid shutdown in case of abnormal conditions. ●  Anti-interference and Isolation:Improve the grounding and electromagnetic shielding design to reduce test interference. ●  Environmental safety:It has functions of over-temperature protection, smoke detection, fire alarm and fire linkage. Summary and Core Logic The intelligent complete set of equipment for inverter aging test can be regarded as a controllable, reproducible and accelerated micro-grid and working condition simulation platform: ●  The power supply and energy feedback unit provides a stable "energy supply"； ●  The load and operating condition simulation unit builds a realistic "electricity demand and harsh environment" scenario.； ●  The data collection and monitoring unit acts as the "intelligent brain and observer"； ●  The interface and switching unit achieve efficient "batch connection and scheduling"； ●  The safety protection unit provides reliable "safety protection" throughout the entire process.； Through the precise coordination of various modules, the inverter aging test equipment can systematically verify the long-term reliability, efficiency attenuation characteristics, heat dissipation design, software stability and process defects of the product. It is the key core equipment for the quality control of inverters at the factory.

The core component of the inverter aging test equipment 4

四,The interface of the tested product and the switching unit (the core actuator) Achieve multi-machine parallelism, high efficiency and reliability, as well as batch testing. ●  Testing fixtures and special jigs:Realize rapid, reliable and consistent wiring for the inverter, with features of error prevention and safety protection. ●  Automatic switching matrix:By using the AC/DC switching matrix, multiple tested inverters can be flexibly allocated with the power supply, load and measurement equipment, significantly enhancing the utilization rate of the equipment. ●  Communication and Protocol Adaptation Module:It communicates with the inverter through interfaces such as CAN, RS485, Ethernet, CANFD, etc., to read internal operation data and fault codes, and supports the issuance of control instructions such as remote start/stop and power setting.

The core component of the inverter aging test equipment 3

三,Data collection and monitoring unit (core perception and control center) Real-time monitoring, recording and analysis of the performance parameters throughout the aging process of the inverter are carried out, enabling traceability of tests and data. ●  Data acquisition system    Electric energy parameter measurement: Collect key indicators such as input and output voltages, currents, powers, and conversion efficiencies on both the AC and DC sides. ●  Top-level computer monitoring management system Support custom test procedures: The power rise, steady-state aging, temperature cycling, load shock and other automated sequences can be edited. Real-time graphical monitoring, featuring limit-exceeding sound and light alarms and event recording functions. Long-term data storage, generation of trend curves and test reports, support for fault tracing and statistical analysis reports. Unified and coordinated control is implemented for the interaction and operation of sub-equipment such as AC and DC power sources, loads, and high-temperature environments.

The core component of the inverter aging test equipment 2

二,Load and Operating Condition Simulation Unit (Core Test Execution Module) Simulate the actual operating load and environmental stress of the inverter to accelerate the aging verification process. ●  Programmable AC electronic load / RLC load:Simulate the electrical equipment characteristics, support custom power factor (inductive/capacitive), and verify the inverter's load-carrying capacity. ●  Dynamic load:Achieve stepwise load switching from 0% to 50% to 100%, and test the dynamic response speed and operational stability of the inverter. ●  Environmental Simulation System:Achieve accelerated aging conditions ranging from 65°C to 85°C, accelerate the aging of key components such as capacitors, fans, and magnetic elements, and quickly expose faults related to thermal stress. ●  Ventilation circulation:Centrifugal fan + duct system ensures uniform temperature and removes the heat generated by the products.

The core component of the inverter aging test equipment 1

The core of the inverter aging test equipment is an integrated system that combines power supply and energy feedback, load and operating condition simulation, data acquisition and monitoring, interface and switching unit for the tested product, as well as safety protection. 一,Power Supply and Energy Feedback Unit (Core Power Module) As the energy hub of the aging test equipment, it is responsible for providing stable power supply to the tested inverter and efficiently processing and recovering the output electrical energy. ●  DC power supply simulation:Provide a DC input for the tested inverter to meet the relevant testing requirements. ●  Communication feedback load/grid simulation:It receives the alternating current output from the inverter and realizes efficient power feedback or internal recycling utilization. Compared with traditional resistive loads, the energy-saving rate can reach over 70%. ●  Grid-connected energy feedback:Returning electrical energy to the power grid requires strict requirements for synchronization accuracy, harmonic suppression, and power factor control. ●  DC bus closed-loop feedback:After converting alternating current into direct current, it is fed back to the direct current input terminal to form an internal energy circulation. ●  Power grid simulation:Simulate complex conditions such as voltage fluctuations, frequency drifts, harmonic injections, voltage sags/supershocks, etc., to verify the inverter's adaptability to the power grid and its anti-interference capability.

Do charging stations also need to undergo "check-ups"?

The charging station, when placed in the professional aging testing equipment, needs to undergo thousands of repeated simulated charging cycles. Every electronic component and every interface connection is subjected to extremely rigorous tests far beyond the normal usage intensity - this is the indispensable "health check" for the charging station before it leaves the factory, and the core of completing this check is precisely the aging testing equipment for the charging station. During the aging test, all potential "problems" of the charging station will be thoroughly examined: such as premature failure of capacitors, increased contact resistance of relays, and micro-cracks at solder joints on the circuit board, are all difficult to escape the "sharp eyes" of the testing equipment. These seemingly minor hazards, if not detected and addressed in advance, will not only lead to a decline in charging efficiency and sudden power failure during charging, but also may cause serious safety accidents such as short circuits and fires, threatening the safety of users and the equipment. The massive data collected during the aging test process has become a valuable digital asset for the charging station industry. Through in-depth analysis of these data, manufacturing enterprises can precisely identify the weaknesses in product design and manufacturing processes, thereby optimizing and upgrading the products and promoting the quality iteration of the entire charging station industry. Nowadays, many leading enterprises in the industry have taken the lead in taking action, starting from the aging test data, to establish a full life cycle quality traceability system for charging stations, creating a unique "health record" for each charging station, and achieving full quality control from production to scrapping.   Every safe and smooth charging experience begins with a rigorous aging test. In today's era where energy transition is accelerating and green travel is becoming increasingly popular, it is these invisible "guardians" - the aging test equipment for charging piles - that silently build a secure barrier for charging, making every green journey more reassuring, more reliable, and more guaranteed.

New energy vehicle motor controller aging test equipment

(CPET) focuses on the aging tests of new energy vehicle-mounted electronic products for power electronics, various types of power supply aging tests, energy storage aging tests, inverter aging tests, charging station aging tests, as well as aging test automatic lines and intelligent monitoring software, etc. It is engaged in the research, development, manufacturing, sales and service of multiple related products. With the rapid development of the new energy vehicle market, the motor controller, as one of the core components of new energy vehicles, its reliability and stability are particularly important. Currently, some new energy vehicle motor controllers do not undergo rigorous aging tests under simulated extreme working conditions before leaving the factory. This will bring great safety hazards to the owners. To better serve the society, Zhongyuanyang innovatively developed and launched an aging test equipment that integrates extreme power, voltage, current, liquid cooling, and air cooling of the environment. Through aging simulation tests on the motor controllers, it can early screen and identify quality problems of the motor controllers, significantly improving the reliability and stability of the motor controllers. It has been widely applied in well-known automotive original equipment manufacturers and well-known manufacturers of new energy component electronics, and has received high industry evaluations. The aging test equipment for the CPET new energy vehicle motor controller adopts the currently advanced testing technologies in China. It can simulate various complex working environments and load conditions to conduct comprehensive tests. During the testing process, the equipment strictly monitors and records various test indicators of the motor controller, such as voltage, current, and temperature, and generates an aging test report. It can also connect with the MES system (if available) to upload data, ensuring the accuracy and reliability of the test results. At the same time, the equipment conducts long-term extreme pressure load tests on the motor controller to simulate the actual usage environment, discover potential defects of the motor controller, and improve the reliability and stability of the motor controller.  As the penetration rate of new energy passenger cars and commercial vehicles gradually and steadily increases, the aging test of drive motor controllers has become increasingly important. This is because it directly affects the safety of the lives and property of new energy vehicle owners. Zhongyuanyuan will continue to support automotive manufacturers and component manufacturers to improve the reliability and stability of motor controllers, providing a strong guarantee for the safe use of new energy vehicles. With the continuous development and innovation of science and technology, the aging tests for motor controllers will also be constantly upgraded and improved. Zhongyuanyuan will continue to focus on the research and production of high-quality testing equipment of various types, providing better services and support to its partners, and contributing a small part to the harmonious development of society.

The testing ground of the heart: Aging test of the on-board charger (OBC) in new energy vehicles

In the booming era of new energy vehicles, people's attention is focused on the range of travel, intelligent driving and the cool appearance of the cars, but they rarely pay attention to the "unknown heroes" hidden inside the vehicles. The on-board charger (OBC) - this "energy bridge" connecting the power grid and the car's battery pack - is quietly undertaking the crucial mission of converting alternating current into direct current. And ensuring the safety and stability of this bridge for decades is a "ultimate testing ground" composed of a series of precise and rigorous aging test cabinets. The aging test cabinet emits a low-pitched operating sound, resembling the "time accelerator" of OBC. Here, the aging cabinet simulates the most extreme usage scenarios in the real world under strict standards.  In the "temperature shock chamber", the OBC undergoes verification of its adaptability to extremely hot environments in a high-temperature cabinet; the "power grid pressure testing area" simulates drastic voltage fluctuations from 90V to 265V, and even deliberately creates instantaneous surges like lightning to test the resilience of the circuits. The most astonishing part is the "life acceleration aging bench", which compresses the ten-year usage wear and tear into a concentrated display within a few hundred hours by increasing the current load and extending the operating time.  Each OBC must prove itself in this simulated "lifetime": Can its conversion efficiency remain above 95% continuously during operation? Will its insulation performance deteriorate as it "ages"? Can its cooling system handle the "thermal stress" caused by long periods of full-load operation? Only products that have passed these rigorous tests can obtain the passcode to enter the market. One of the core missions of the aging test is safety verification. Every rigorous experiment conducted within the test chamber is a solemn commitment to the safety of consumers' lives and property. The short-circuit protection test verifies whether the power supply can be cut off within milliseconds in case of circuit abnormalities; the leakage current monitoring ensures that no dangerous voltage is generated even in a humid environment; the insulation withstand voltage test applies high-voltage electricity several times the working voltage to test the reliability of every insulation gap.  The engineers from Zhongkong Yuan, a well-known manufacturer of aging test cabinets in the industry, often say: "What we test is not the product, but the risk boundary." It is precisely this zero-tolerance attitude towards risks that enables the OBCs that pass the complete aging test to ensure the charging safety of vehicles in complex conditions such as thunderstorms, humid environments, and unstable power grids, and prevent the occurrence of serious accidents like spontaneous combustion.