Chroma ATE introduces the 8620 OBC and DC-DC Converter Power HIL Testbed, equipped with comprehensive testing capabilities for EV charging and powertrain components. The system's flexible hardware configuration allows it to meet DUT specific testing requirements. Options include programmable DC power supplies, programmable DC electronic loads, digital power meters, and oscilloscopes. This versatile testbed supports various system architectures and provides advantages such as scalability and platform sharing.

The Chroma 8620 is specifically designed for the R&D of on-board chargers (OBC) and DC-DC converters. It features user-friendly software with graphical user interfaces for monitoring and control, manual and automated testing, and automated test report generation. This suite of capabilities meets the needs of high-volume, repeatable testing, enhancing both test coverage and efficiency.

The Chroma 8620 supports loading of Simulink-based vehicle models. This allows customers to leverage their existing models without the hassle of time-consuming redevelopment. Additionally, the system supports CAN HS/FD and LIN communication interfaces for loading of DBC and LDF files.

Besides simulating the DUT's normal operating conditions in real environments and verifying its functionality, the Chroma 8620 can also simulate abnormal operating conditions, including communication anomalies and signal faults (open circuit, short to ground, short to battery, pin-to-pin short). By identifying potential hazards that may occur during charging or driving, this pre-vehicle testing approach not only prevents accidents and reduces risks but also significantly lowers the costs associated with whole-vehicle testing.

The Chroma 8620 OBC and DC-DC Converter Power HIL Testbed supports Hardware-in-the-Loop testing compliant with the ISO 26262 V-model for functional safety in automotive development. It covers failure modes, functional hazard analysis, and potential risk mitigation for on-board chargers (OBC) and DC-DC converters in the design stage of the V-model. Various vehicle operating conditions can be simulated on the platform, enabling users to identify and correct issues early in development before whole-vehicle trials, helpful in obtaining Automotive Safety Integrity Level (ASIL) certification.
The testbed's versatile architecture supports expansion or replacement of peripheral equipment to meet the testing needs of different DUT specifications. Existing configurations can be easily modified for new projects, eliminating the need to start from scratch. The Chroma 8620 enables users to perform highly repeatable automated tests, reducing errors caused by operator fatigue during long manual testing sessions. These capabilities combined significantly reduce the number of whole-vehicle tests required, cut development costs, shorten testing schedules, and improve testing efficiency.

The Chroma 8620 employs a flexible software architecture that enables loading of CAN HS/FD and LIN communication files. It combines real-time systems, power equipment, measurement instruments, and mathematical vehicle models for dynamic real-time testing of OBCs and DC-DC converters. Users can flexibly edit the user interfaces and automated test sequences during manual or automated testing. Automated testing supports higher-level testing software using the ASAM XIL interface. Upon completing automated test procedures, the platform generates test reports automatically for convenient review of test variations and results. Test data can also be recorded and stored in TDMS, CSV, or Text format for further analysis.

The 8620 platform supports testing of three DUT architectures: OBC, DC-DC, or OBC + DC-DC. Both the user interface and automated test sequences can be repeatedly edited or duplicated for adaptation to new DUTs or projects. The automated test sequences support programming in familiar languages such as LabVIEW, C/C++, Python, and .NET, promoting reusability across R&D teams, avoiding duplicate engineering work, and improving overall development efficiency.

The Chroma 8620 offers a highly customizable software platform for creating automated test sequences. Beyond (editable) standard regulatory tests for OBCs and DC-DC converters, the testbed can also be custom-programmed for DUT functional testing, including power cycling, normal and abnormal communication behaviors, and signal fault injection. The system can simulate various control sequences, timing variations, and fault behaviors, enhancing overall test coverage. This enables execution of tests that cannot be performed on complete vehicles, preventing costly and dangerous field failures, and allowing early completion of hazard analysis and risk assessment.

The software platform's customizable user interfaces are based on integrated power equipment, measurement devices, and vehicle models. Through the UI, users can conduct test operations and monitor data in real-time, including parameter changes, chart displays, and signal status, offering both user convenience and testing efficiency.

The Chroma 8620 supports customized hardware configurations, offering dedicated Power HIL main cabinets and auxiliary cabinets that integrate power equipment for optimal use of test space. An independent PLC monitoring system provides real-time monitoring of system software and power equipment operation status, promptly activating protection and warning mechanisms to prevent damage to equipment and DUTs.