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Battery Emulator

EV Battery emulators for testing electric vehicle propulsion and powertrain systems, including traction inverters, E-motors & E-axles.

Test your EV and HEV propulsion systems with a UNICO EV Battery Emulator.

This outstanding EV battery emulator comes standard with programmable voltage and current controls for resistance simulation, so you can quickly test and view results for hundreds of different battery designs on powertrain performance. With the programmable slew rate, you can precisely regulate the response to a change in both the requested output and changes in the load. And with a full filtered output, systems can be designed with minimal current and voltage ripple – typical ripple is less than 1%.

Features

Testing Applications

Testing of different battery designs and power ratings on the EV propulsion system to evaluate efficiency, durablilty, and performance response of the traction inverter, E-Motor, and E-Axle.

Precision Control and Flexibility

Unico inverters achieve a high sampling frequency with silicon IGBTs, ranging from 1 kHz (1.0 ms) to 10 kHz (0.1 ms). This provides quick response to changing commands or load levels. Performance can be customized to your application.

Common DC bus architecture allows for add-on dynamometer controls sections, high efficiency, fully regenerative current source and sink capability. Higher voltage and current possible by connecting units in series and parallel. The optional ripple generator (inject AC wave on top of DC output) is available for specialized testing. Full bridge models have 0-volt operation for applications like fuel cell testing.

For stand-alone battery emulators, systems can be designed to recycle regenerated power back to the three-phase grid bus. This eliminates the need to dump valuable power into resistors.

Preprogrammed

With the programmable slew rate, you can precisely regulate the response to a change in both the requested output and changes in the load. And with a full filtered output, systems can be designed with minimal current and voltage ripple – typical ripple is less than 1%.

Control voltage to a constant or dynamic set point, regardless of the current draw. This removes the variability of battery performance, so you can accurately test efficiency and response of your vehicle’s traction inverter, E-Motor, and E-Axle.

High Speed Link

Supports most industry standard communication protocol, making it versatile to work with any available automation system platform. A high-speed communications interface is optionally available to accept commands from existing customer controllers that are used to generate test profiles. Wired and fiber-optic options are available. Supported protocols include:

  • CANopen
  • CC-Link
  • ControlNet
  • DeviceNet
  • Ethernet
  • EtherCAT (async)
  • Interbus
  • LonWorks
  • Modbus Plus
  • Profibus DPV1
  • Profibus Master
  • EtherCat (sync)

Safety and Protection

Built-in safety and control interlocks are hardwired, opto-isolated, and software configurable, so you can match the demands of your EV propulsion system under test.

Specifications

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Unico Features

General Specification

AC Input 480VAC, 3Ph, 50/60Hz (other voltages available on request)
Ambient Up to 40°C, max l000m above sea level, 95%RH non-condensing enclosure
Enclosure NEMA 1 (other options available upon request)Cabinet Paint
Cooling Air cooled (water cooled or airconditioned cabinets upon request)
Cabinet Paint RAL 7035 rough semi-gloss poly powder finish
Certification Compliance UL (other certifications available)
Control Modes Constant current, constant voltage, constant power
Control Local and remote
Built in remote interface Analog as well as RS-422, RS-485, two ports (other interface and protocol, see options below)
Safety and control interlocks Hardwired, opto-isolated, software configurable
Measurement Accuracy 0.05% (system calibration required)
Measurement Accuracy 0.05% (system calibration required)
Voltage Ripple 0.10%
Current Ripple 0.10%
Unico Features

Options

Isolation transformer Various sizes as requiredr
Insulation monitoring Available
Remote voltage sensings Available
Additional analog and digital input, output Technical discussion required
Cabinet paint finish Customer specific
Protection class NEMA 12
External communication interface CANopen, CC-Link, ControlNet, DeviceNet, Ethernet, EtherCAT (async), Interbus, LonWorks, Modbus Plus, Profibus DPV1, Profibus Master, EtherCat (sync)

Block Diagrams

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Brochures

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Resources

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Application used for Automotive

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Battery

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Inverter

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Inverter

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Battery

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Inverter

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Battery

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Inverter

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Battery

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Inverter

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Battery

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Fuel Cell

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Frequently
Asked Questions

A battery cycler measures the cell response over time and analyzes battery function by charge/discharge cycles. The parameters you can calculate using a battery cycler include capacity, self-discharge, and efficiency, among others. You can also use a battery cycler with capacitors and super-capacitors. 

It is effortless to use a battery cycler system, and you can use it simply by following these steps:

  1. Turn on the multimeter and then choose the mode named ‘DC voltage’.
  2. Now, connect the multimeter test leading to the battery terminals. 
  3. Read the voltage shown on the gauge or multimeter display.
  4. Load the battery with a satisfying result or repeat the process.

The Unico battery cyclers combine the family of single and dual output DC power supplies with software specifically tailored for testing HEV battery packs, ultra and supercapacitor packs, fuel cells, power electronic converters, and other devices.