High voltage large capacity inverter evaluation

Inverter Evaluation

In recent years, the voltage and capacity of inverters used in the BEV and PHEV powertrains have increased.

We would like to introduce solutions for inverters that repeatedly supply and regenerate power.

Inverter Evaluation
Bidirectional High-Capacity DC Power Supply PXB Series

EV inverters not only control the motor and supply it with power from the battery but also charge the battery with regenerative power from the motor. However, quantitative evaluation of inverters using real batteries is not an easy task. This is because batteries change their state as they are repeatedly charged and discharged. Therefore, we recommend using the PXB series of bidirectional high-capacity DC power supplies instead of batteries.

The PXB series is designed for high-voltage, large-capacity inverters and other electrical components. It supports voltages up to 1500 V and power up to 200 kW (power over 200 kW is available on request). To accommodate larger capacitive loads, the PXB series outputs stable waveforms even when several mF are connected. In addition, the power regenerated to the PXB series is AC regenerated to the primary side, allowing for energy reuse. This reduces power consumption and contributes to carbon neutrality.

Inverter with repeated power and regeneration.PXB SeriesTOS9300 SeriesPCR-WEA Series

Features of the PXB Series

  • Available voltages: 50V, 500V, 1000V, and 1500V.
  • Compact size & large capacity: 20kW capacity in a single unit. Compact size with a height of 3U (132mm). Expandable up to 200 kW in parallel connection (more than 200 kW available on request).
  • Resistant to capacitive loads: Output is stable even when connected to several mF.
  • High-speed response: CV rise time of 10 ms and CC rise time of 5 ms.
  • Input voltage can be selected from 3-phase 200V and 400V. Full 20 kW output, regardless of the input voltages.
  • Built-in sequences: Supports high-voltage power fluctuation tests such as ISO21498-2.

Supporting High Voltages and Large Capacities

Batteries used in EVs have much higher voltages than the standard 12V. Currently, most batteries are around 400V, and in the future, the voltages are expected to increase to 800V~1,000V. Motor capacities are also growing. They range from 50kW to 300kW, depending on the type of vehicle.

In addition to the PXB series, we offer various power supplies that can handle high voltages and large capacities, such as the PCR-WEA/WEA2 series, PAT-T series, and PHP-T series.

Supporting High Voltages and Large Capacities

Evaluation of DC-DC Converters

Evaluation of DC-DC ConvertersPXB SeriesPXB Series

Required voltages for DC-DC converters vary depending on the purpose and application. Electronic loads corresponding to the right input and converted voltages are essential for evaluation. Also, in bidirectional DC-DC converters, power is frequently supplied and regenerated. In this case, using a bidirectional power supply is recommended.

KIKUSUI’s power supplies and electronic loads are ideal for the DC-DC converter evaluation!

For the evaluation of bidirectional DC-DC converters:

  • Bidirectional high-capacity DC power supplies are a great choice!
    • Available voltages: 50V, 500V, 1000V, and 1500V.
    • Compact size & large capacity: 20kW capacity in a single unit. Compact size and 3U (132mm) height. Expandable up to 200kW in parallel connection (more than 200kW is available on request).
    • Power and regeneration in a single unit!
  • Aging tests: The PXB series regenerates energy to the primary side. With 90% regenerative efficiency, power consumption is greatly reduced, which also lowers the cost of electricity. [Ecology & Economy]

Unidirectional DC-DC converter evaluation:

  • Verifying operational range of DCDC converters.
    • Various PAT-T series voltage lineups are available (250/350/500/650/750/850/1000/1500V).
  • Verifying DC-DC converter performance under sudden load changes.
    • High-speed, high-voltage, high-capacity PLZ-5WH2 series reproduces steep current (up to 1000V, 20A/μs).
Kikusui's Electronic LoadPLZ-5WH2 SeriesPAT-T Series

Ripple Superimposition Testing

In the ripple superposition testing, AC ripple voltage is superimposed on the base battery voltage. To superimpose an AC voltage, in addition to a bipolar power supply with adequate frequency characteristics, a transformer with sufficient frequency bandwidth is necessary. Moreover, some test loads have large capacitors and require a large current from the superimposed source.

Ripple Superimposition Testing

The diagram below shows a ripple superposition testing. PLZ-5WH2 electronic load is used instead of the testing load. The PXB series of bidirectional high-capacity DC power supplies simulates a battery. The PBZ series of bipolar power supplies, capable of outputs up to 150 kHz, is used as the superimposed power source. In this experiment, a 100A model was selected, assuming that a large current is required for the superimposed source of 1 kHz to 10 kHz.

Ripple Superimposition TestingPBZ SeriesPXB SeriesPLZ-5WH2 Series
Waveforms
  • High voltage/high power DC output: Up to 1500V/200kW
  • High frequency/high ripple voltage: 10Hz~150kHz / ~ 40V
  • Supports standard testing: ISO21498-2

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