Shenzhen CPET Electronics Co., Ltd.

The working principle of the intelligent equipment for aging test of the CPET vehicle power supply assembly

The on-board power assembly is the core "energy hub" of an electric vehicle, integrating three key components: the on-board charger (OBC), the DC/DC converter, and the high-voltage distribution box (PDU). It can be designed as an independent unit or a two-in-one/three-in-one/multi-in-one integrated unit according to application requirements. As the core module of the vehicle's "electronic control assembly", it undertakes the core functions of electric energy conversion, transmission, and management between the external power grid and the battery power supply, the high-voltage system and the low-voltage system. It directly determines the charging speed, power efficiency, and operational stability of the electric vehicle. Product reliability is also an important guarantee for the safety and core performance of the entire vehicle. Therefore, conducting accelerated durability and lifespan tests on the on-board power assembly during the finished product stage is a key section for product quality verification, and professional aging testing equipment is the core technical support for this process.   The CPET new energy vehicle power supply assembly temperature control liquid cooling integrated aging test intelligent equipment is specially developed and designed for vehicle power supply assemblies (three-in-one/multi-in-one). It can conduct long-term aging, reliability verification, thermal management matching, and extreme condition simulation tests. It precisely resolves the industry pain points of traditional air-cooling aging equipment, such as uneven temperature distribution, low temperature control accuracy, insufficient heat dissipation capacity, and inability to replicate the actual vehicle liquid cooling conditions. It provides professional and efficient testing solutions for improving the reliability of vehicle power supply assembly products.   This equipment simulates, accelerates and strengthens the electrical, thermal, mechanical and environmental combined stresses that the on-board power assembly may encounter during actual use. It can expose the potential design flaws, performance degradation patterns and failure modes of the product in a much shorter period of time than the actual product lifespan. This provides scientific and precise experimental data basis for product design optimization, process improvement and reliability enhancement. The equipment adopts the core working logic of "maximum power pressure loading + liquid cooling temperature control cycle + ultra-high temperature ambient temperature control + multi-parameter full-dimensional monitoring + intelligent closed-loop collaborative control" to accurately replicate the real working scenarios of the on-board power assembly. The core working principle is as follows: When the tested on-board power assembly operates continuously under full power or variable power conditions, the internal OBC, DC/DC power components, inductors, capacitors and other core components will generate a large amount of heat loss. The equipment uses a dedicated liquid cooling circuit to precisely deliver the coolant to the internal flow channels of the power assembly, forcing the heat generated to be discharged, and through precise temperature control technology, stabilizes the temperature of the core components at the set range of 85℃ to 125℃.   At the same time, the system simultaneously collects key parameters such as temperature, flow rate, pressure, voltage, current, efficiency, insulation, etc. from all dimensions, and feeds them back to the central control unit in real time. It dynamically adjusts the cooling efficiency of the liquid cooling system and the intensity of power loading, establishing a "thermal-electric-fluid" multi-closed-loop collaborative control system. It precisely simulates extreme working conditions such as high and low temperature cycles, thermal shock, continuous full load, and start-stop shock of the entire vehicle, achieving efficient acceleration of the product aging process and precise exposure of early failure issues.   To achieve high-precision replication of the actual temperature conditions of the entire vehicle, the equipment is equipped with two core temperature control units: the liquid cooling temperature control circulation system and the ambient temperature control circulation system. It integrates the classic PID control algorithm and the AI intelligent algorithm to construct the temperature control logic. It can flexibly adjust according to the testing requirements and efficiently reproduce the temperature environment of the vehicle power supply assembly in the actual operation of the entire vehicle, ensuring the authenticity and accuracy of the testing scenario.   The equipment is equipped with a complete extreme power pressure loading system, which can fully replicate the actual power environment of the product's operation: The AC input end can provide 220V/380V three-phase/single-phase AC power supply, accurately simulating the actual input scenarios of household sockets and public AC charging piles, supporting ±20% voltage fluctuation, frequency fluctuation and harmonic injection, and capable of reproducing abnormal working conditions such as unstable grid voltage and harmonic interference; The DC high-voltage end can output a 300V~1200V high-voltage DC source, accurately simulating different working states of power batteries such as full charge, depleted charge, and dynamic voltage, supporting voltage step changes and ripple superimposition, and covering all kinds of power working scenarios of the vehicle power system during vehicle operation.   At the same time, the equipment is equipped with a high-performance multi-parameter monitoring and data acquisition system, which enables precise capture, efficient storage and intelligent management of all-dimensional data during the testing process. It can complete the detection and precise control of ambient temperature, as well as the detection of flow, pressure, liquid level, medium temperature and leakage status of the liquid path system, high-precision detection of electrical parameters such as voltage, current, power, insulation resistance, leakage current, etc., and full-dimensional detection of product functions including OBC charging status, DC/DC output voltage stabilization performance, PDU on-off and protection functions, CAN/LIN communication status, and fault code reading. The system supports high-speed data acquisition with customizable sampling frequency, enabling local secure storage of aging test data, and also supports seamless connection with the enterprise MES system for data cloud upload. It has functions such as viewing of test history curves, automatic generation of aging test reports, and intelligent analysis of product failure modes, providing comprehensive and precise data support for product design optimization and process improvement.   Intelligent control and all-scenario security protection are the core competitive advantages of this device: The system adopts a highly stable architecture of industrial PLC + upper computer software, is equipped with professional aging test software for computer monitoring, supports users to customize the aging test process, can flexibly set key parameters such as aging duration, power curve, temperature curve, and cycle times, and realizes the automatic and intelligent multi-closed-loop collaborative control of the "power loading → heat generation → liquid cooling cooling → temperature feedback → dynamic adjustment of loading/cooling" test process flow.   In terms of safety protection, the system adopts a comprehensive scenario-enhanced design. It can respond quickly within milliseconds and trigger emergency shutdown protection for various abnormal situations that may occur during the equipment operation, such as overheating, overvoltage, overcurrent, undervoltage, leakage in the liquid path, insulation failure, etc., ensuring the safety of the testing equipment and the tested products. At the same time, the equipment supports multiple industrial communication methods such as CAN3.0, CANFD, RS485, and TCP/IP, enabling remote real-time monitoring of the testing process and full-process traceability of the test data, significantly improving the efficiency and operational convenience of aging tests. In summary, the CPET Zhongyuan New Energy Vehicle Power Supply Assembly Temperature Control Liquid Cooling Integrated Aging Test Intelligent Equipment is essentially a professional reliability verification platform for vehicle power supply assemblies, integrating time acceleration and pressure simulation. It achieves "short-term advance" of product service life in the laboratory environment through precise multi-physical field coupling control and accelerated stress technology. It compresses the risks of vehicle power supply assembly usage on the road for months or even years into a few days, enabling early detection and resolution, providing crucial engineering technical support for enhancing the reliability and safety of new energy electric vehicles. At the same time, it also provides core technical support for the rapid iterative upgrade and continuous quality improvement of vehicle power supply assembly products.

Mobile power supply aging test process

Aging tests are a crucial quality inspection step in the production process of mobile power supplies. The core purpose is to verify the stability, safety and performance reliability of the products during long-term use, to identify potential faulty products, and to strengthen the quality defense line before leaving the factory.To ensure the accuracy of the test results and the standardization of the process, the specific test procedures are as follows: 1. Initial state check Place the mobile power bank to be tested (in its bare or semi-finished state) at the designated testing workstation. Complete the following comprehensive checks one by one to ensure that the initial state of the product complies with the testing standards: The appearance should be free of damage, scratches, deformation and obvious color differences; The buttons should press smoothly, have sensitive rebound, and there should be no sticking, malfunction or abnormal pressing feedback.The TYPE-C input/output interface is free from looseness, oxidation, or damage. The insertion and removal feel smooth. The pins of the interface show no bending, deformation, or damage. Only when all the initial conditions are met can the subsequent automatic aging test be carried out, to prevent the test results from being affected by initial defects. 2. Discharge test First, fully charge the mobile power bank to be tested. Then connect it to the Zhongyu Aging Test System. The system will discharge the battery at a constant current according to the preset standards until the cell triggers the protection voltage (the conventional standard is 3.0V per cell). The test system will automatically stop the discharge. The entire testing process is precisely recorded by the system for the discharge duration, and the actual output energy of the mobile power bank is calculated. This data directly determines the number of times it can charge devices such as mobile phones and tablets, and is one of the core indicators for evaluating the product performance. 3. Charging test After the discharge test was completed, the aging test system of Zhongkongyuan automatically connected the mobile power supply to the charging module. It was compatible with mainstream fast charging protocols such as UFCS integrated fast charging, USB-PD, FCP, SCP, Super VOOC, Mi Turbo Charge, Flash Charge, QC5, etc., precisely simulating the daily charging scenarios. During the test, the system monitored the entire charging process in real time, focusing on recording the curves of voltage and current changes, to verify whether the product could switch to constant current charging (during the fast charging stage) or constant voltage charging (during the trickle charging stage) modes, ensuring a stable charging process without abnormal fluctuations in voltage or current, or situations such as premature stopping of charging, overcharging, or insufficient charging. Ultimately, it could fully charge the battery without any abnormal issues such as premature stopping of charging, overcharging, or insufficient charging. 4. Cyclic charging and discharging test For mobile power supplies with high-quality standards, the "charging-discharging" complete process needs to be repeated for 3 to 5 cycles for testing. Through multiple cycle tests, the cycle life and capacity degradation rate of the battery cells, as well as the long-term thermal stability of the circuit board and the reliability of the charge-discharge protection mechanism are further verified. Precisely identify potential faults that may occur in the product during long-term repeated use, and ensure that the product meets the requirements for long-term use. 5. Data recording and exception handling The computer-monitored aging equipment provided by Zhongke Yuan's aging testing system can collect and automatically record the key parameters of each mobile power supply during the entire testing process in real time, including charging/discharging voltage, current, cell temperature, test duration, etc. This ensures that the data is traceable and verifiable. Before the test, the staff preset the safety thresholds for each parameter. Once the system detects that a certain parameter exceeds the threshold (such as excessively high cell temperature, abnormal voltage fluctuations, sudden increase or decrease in current, etc.), it will immediately send an alarm signal and automatically cut off the testing channel to prevent the expansion of the fault. At the same time, it marks the abnormal products to facilitate the subsequent technicians in identifying the cause of the fault and implementing corrective measures. Summary The Zhongyuanyuan aging test system is the core support for quality control of mobile power supplies - for manufacturers, it can effectively screen out faulty products, strengthen brand reputation, and reduce the rate of after-sales faults; for consumers, it is the last important line of defense to ensure daily usage safety, guarantee product performance compliance, and enhance the usage experience. It is both the "passport" for product manufacturing and the "pillar of confidence" for consumers to use the product with peace of mind.

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.