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How modern power supplies contribute to connectivity in automotive test environments.

Modern power supplies are key components in networked industrial test environments. To meet the increasing demands of battery and high-power systems in electric vehicles, these instruments must offer far more than simple power delivery. As integral elements of automated test systems in the era of Industry 4.0, they make a decisive contribution to the efficiency and safety of current and future test and validation tasks. This article highlights the functionalities of modern power supplies that are crucial for building productive and flexible test systems capable of addressing technological developments in the automotive sector in a future-proof and economical manner.

The demand for productive test and validation systems is increasing with the rapid technological progress in the automotive sector, particularly in e-mobility. Complex battery storage systems, fuel cells, on-board controllers (zone controllers), and on-board chargers must be tested safely and reproducibly. New designs should be transferred efficiently into production. With each new generation of these high-power systems, test requirements and parameters change. Consequently, building a flexible system that can adapt to current and future test requirements is becoming increasingly important.

In implementing connected test strategies, modern bidirectional DC power supplies assume a central role. Programmable power supplies make an essential contribution to efficiency, safety, and digitalization in automated test environments and fulfill key requirements in the Industry 4.0 era—from optimizing energy efficiency to minimizing space requirements and operating costs.

Requirements for Power Supplies in Test Automation.

For demanding automotive test applications, power supplies must meet both technical and economic requirements. A central aspect is data communication via standardized interfaces such as Ethernet, CAN, or RS-422/485. This enables seamless integration of power supplies into PLC-based automation environments and centralized control.

An often underestimated factor is digital control latency. It should be as low as possible because, especially in real-time applications, deterministic signal processing with predictable response times is essential. To ensure maximum control precision, many users additionally rely on analog remote control; therefore, the PLC should support both digital and analog interfaces.

System scalability also plays a major role. Power supplies should be designed so that installed power can be easily expanded as demand increases. Modular architectures or the option to connect multiple units in parallel or in series provide maximum flexibility, investment protection, and future readiness.

To achieve maximum output power per rack unit (RU), high power density is crucial. This ensures efficient use of available space, particularly in compact test systems or production environments with limited floor space. High efficiency with regenerative energy feedback to the grid minimizes energy losses and additional cooling requirements, thereby reducing operating costs. Considering the total cost of ownership (TCO) over the entire lifecycle is essential for investment decisions.

Cooling flexibility can also be an important criterion. Depending on the ambient conditions, a modern power supply should be available with either water or air (fan) cooling so that the cooling concept can be optimally matched to the existing infrastructure.

Integrating Modern Power Supplies into the Test Environment.

In the context of Industry 4.0, automating test sequences is a primary objective.

Modern power supplies feature standardized communication interfaces (e.g., USB, CAN). This enables seamless integration into networks and higher-level test and control systems (e.g., PLCs) with fast, reliable data exchange between the power supply, test-stand controller, and other measurement and automation components. Using standardized command protocols such as SCPI or Modbus, control commands, measurement data, and status information can be exchanged, simplifying system integration.

Modern power supplies not only deliver energy but also perform measurement, monitoring, and control functions. They record operating data, monitor limits, and can automatically trigger protective measures in the event of a fault. The collected data is transmitted to central systems, enabling comprehensive analysis and optimization of test processes.

Power-Supply Functionalities in the Automotive Test Environment.

Modern power supplies support unified, centralized test environments—ideal for connected test strategies in the automotive sector. The focus is on future-ready, scalable, and economical test solutions that meet the growing challenges of e-mobility. Programmable DC power supplies are essential building blocks of an intelligent test concept aligned with Industry 4.0 principles. Their technology enhances not only efficiency but also safety in the complex test environments of the automotive industry, primarily through the following key functions:

Bidirectional Functionality:
Units can operate both as voltage/current sources and as electronic loads (sinks), saving space and capital expenditure.

Regenerative Energy Feedback:
With efficiencies up to 96.5 %, these sustainable devices enable substantial energy and cost savings.

Autoranging:
Flexible output stages allow operation across a wide voltage and current range for versatile test applications.

Modularity and Scalability:
Multiple units can be linked via bus systems to increase total power. Centralized control and monitoring are significantly simplified.

Automotive-Specific Applications:
Battery simulation functions allow precise reproduction of real-world scenarios, such as drive tests, battery recycling, second-life analysis, fuel-cell, or on-board-charger tests.

Protective Functions:
Integrated protection mechanisms—such as overvoltage, overcurrent, overload, and overtemperature protection—ensure safe operation even when handling high currents and voltages.

EA-PUB 10000 6U DC Power Supply.

With the EA-PUB 10000 6U series, Elektro-Automatik offers a high-performance solution for industrial test environments. Typical applications include testing power electronics in electric vehicles, on-board chargers, fuel cells, and batteries, as well as battery simulation and testing processes in battery recycling. These programmable power supplies deliver 60 kW per 6U unit and, with a wide range of standardized interfaces, are ideally suited for integration into networked test environments. Using master–slave and share-bus technology, up to 64 units (max. 3.84 MW) can be combined into a single system. This simplifies the scaling of test capacity and centralized monitoring of all test parameters. Software tools such as EA-Power Control and EA-Battery Simulator support efficient management, control, and documentation of test processes.

Series

EA Elektro-Automatik
PUB10000 Series

Bidirectional DC power supply units, 1 channel, up to 2,000 V, up to 480 A, 60 kW, 6 U

Price depending on choice of model

Select now

Series

EA Elektro-Automatik
PUB10000 Series

Bidirectional DC power supply units, 1 channel, up to 2,000 V, up to 1,000 A, 30 kW, 4 U

Price depending on choice of model

Select now

Power-Supply Requirements Driven by Modern Vehicle Electronics.

The increasing complexity and power density of modern vehicle electronics pose particular challenges for test environments and the power supplies used within them. Ever more powerful battery systems, high-voltage components, and numerous sensors and actuators require a dynamic, precise, and safe power source. Only with appropriate measurement technology can quality and safety in the development and validation of vehicle electronics be ensured over the long term. Test systems must be flexible and adaptable to reliably verify new functions and configurations while keeping pace with the industry’s innovation cycles.

Key Challenges for Power Supplies in the Automotive Test Process:

High charging power and fast-charging technologies:
The spread of ultra-fast charging stations with outputs of 350 kW and above demands power supplies capable of providing high currents and voltages precisely and safely.

Bidirectional charging and vehicle-to-grid (V2G):
Power supplies must not only deliver but also absorb energy and feed it back to the grid, which places particular demands on controllability and safety.

Fast response and real-time capability:
Complex ECUs and battery-management systems require dynamic, low-latency supplies to simulate rapid load steps and realistic driving conditions—for example, in hardware-in-the-loop (HIL) test benches.

Diverse communication standards:
Integration into automated test environments requires power supplies with versatile, standardized interfaces (e.g., CAN, Ethernet, Modbus).

Enhanced safety requirements:
With increasing energy density and system complexity, monitoring and protection functions become more critical to prevent damage to DUTs and to ensure operator safety.

Safety-critical components:
Systems such as braking, battery management, or driver assistance are safety-relevant; deviations in power supply can have serious consequences. Precise power supplies are essential for validating the reliability and safety of such components under realistic conditions.

High test coverage:
Comprehensive, automated tests are necessary to cover all operating states and scenarios, including boundary and fault conditions.

Standards compliance:
Automotive components are subject to stringent international standards (e.g., ISO, IEC). Compliance requires precise measurement and test conditions that only high-accuracy power supplies can provide.

Summary and Outlook.

Modern power supplies make a decisive contribution to improving efficiency and safety in the demanding test environment of the automotive industry. The focus is on future-ready, scalable, and economical solutions that address the growing requirements and rapid development cycles of e-mobility. Devices such as the EA-PUB 10000 6U series fulfill key functions in networked, automated test systems and offer the flexibility required for upcoming technologies. As development continues in areas such as autonomous driving, fast-charging infrastructure, and advanced battery systems, the demand for productive test and validation systems—and for precise, high-performance power supplies—will continue to rise. Modern power supplies provide far more than power delivery: they are integral components of centralized, self-optimizing test systems for the next generation of vehicle electronics.

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