DS5367 Smart Charging Plug Simulator
Emulating and manipulating the physical connection between EVs and EVSEs
The new DS5367 Smart Charging Plug Simulator is an extension to the dSPACE Smart Charging Solution. It lets you emulate and manipulate the electrical interface between an electric vehicle (EV) and the electric vehicle supply equipment (EVSE), and thereby supports all common charging communication standards.
- High-precision resistors as well as digital and analog I/O for emulating resistor networks of EVs, EVSEs, and charging plugs
- Manipulation of the electrical interface and communication lines between EV and EVSE for failure simulation
- Simulation of plug-in and plug-out scenarios via connector buttons and locking actuator controls
- Support for all common charging plugs (e.g., Type 1, Type 2, CCS1, CCS2, GB/T, CHAdeMO, ChaoJi)
- PWM signal generation and measurement for AC charging scenarios
- CAN communication for DC charging scenarios according to GB/T, CHAdeMO, and ChaoJi
- Compatibility with the DS5366 Smart Charging Interface for DC charging scenarios according to ISO 15118 / DIN SPEC 70121
- Voltage and signal generation and measurement
- Option to connect temperature sensors (PT1000 1, PT1000 2) for plug temperature measurement
- CAN FD control via HIL simulator
The Smart Charging Plug Simulator is equipped with high-precision resistors, including typical resistance values of the proximity pilot (PP) (100 Ω , 220 Ω, 680 Ω, and 1.5 kΩ) and control pilot (CP) (1 kΩ, 2.74 kΩ, 1.3 kΩ) with a deviation of less than 0.1%. These resistors meet the CharIN CCS Test System (CCTS) specification defined by CharIN e.V..
For GB/T, CHAdeMO, and ChaoJi, the Smart Charging Plug Simulator is equipped with equivalent high-precision resistors for CC1, CC2, CC, CSS, and PD.
Test Setups
The following illustration shows the setup for emulating and manipulating the electrical interface between an electric vehicle (EV) and the electric vehicle supply equipment (EVSE) in connection with the CHAdeMO, GB/T, or ChaoJi charging communication standards.
Besides the DUT, the setup includes the DS5367 Smart Charging Plug Simulator and a dSPACE HIL simulator.
The following illustration shows the setup for emulating and manipulating the electrical interface between an electric vehicle (EV) and the electric vehicle supply equipment (EVSE) in connection with the ISO 15118 / DIN SPEC 70121 charging communication standards.
Besides the DUT, the setup includes the DS5367 Smart Charging Plug Simulator, the DS5366 Smart Charging Interface and a dSPACE HIL simulator.
Emulating Resistor Networks of EVs, EVSEs, and Charging Plugs
To easily connect a dSPACE HIL simulator to your device under test (DUT) in both EV and EVSE simulation use cases, the DS5367 Smart Charging Plug Simulator is equipped with high-precision resistors, digital and analog I/O as well as CAN communication interfaces. You can emulate any charging state and the ampacity coding of the charging cable, for example, which gives you full control over the charging process.
The DS5367 Smart Charging Plug Simulator supports the following charging standards:
- ISO 15118 / DIN SPEC 70121 (in combination with the DS5366 Smart Charging Interface)
- CHAdeMO
- GB/T
- ChaoJi
Manipulating the Electrical Interface and Communication between EV and EVSE
The DS5367 Smart Charging Plug Simulator measures and analyzes all the electrical signals relevant for the charging process:
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Variation of the voltage level (Range: 10 V … 14.5 V) and frequency of the generated PWM signal (Range: 800 Hz … 1200 Hz)
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Variation of the CP state (Range: 60 Ω … 1 MΩ)
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Variation of the charging cable ampacity coding indicated by the resistance value of the PP resistor
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Variation of the EV diode forward voltage by switching different EV diode variants
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Insertion of electrical CAN communication errors
In addition, you can test the failure detection of your device under test (DUT) with the following failure insertion options:
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Insertion of leakage resistances (Range: 60 Ω … 1 MΩ)
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Short circuits of all signal lines to protective earth (PE)
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Interrupt of all signal lines
Measurement features
The DS5367 Smart Charging Plug Simulator measures and analyzes all the electrical signals relevant for the charging process:
- Measurement of the proximity pilot (PP) and control pilot (CP) voltages, as well as measurement of the corresponding voltages for GB/T, CHAdeMO, and ChaoJi
- Measurement of the PWM signal frequency on the CP pin
- Measurement of the charging plug temperature
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