Application of NGI test system in automotive BDU test

In this era of continuous iteration and development of electric vehicles, the core and key components of electric vehicles, such as batteries, battery management systems, and motor systems, are related to the basic lifeline of the industry. Each of these components will have a significant impact on the entire vehicle in different aspects. Take BDU as an example. BDU is a battery pack circuit breaker protection unit for passenger cars, which is widely used in the electric vehicle industry. BDU is directly connected to the power battery through a high-voltage plug-in. It controls the charging and discharging process of electric vehicles, plays a major role in the power-on of high-voltage components, circuit overload short-circuit protection, high-voltage sampling, etc., and is a vital component in the high-voltage circuit.

At present, BDU is mostly customized according to the needs of the car manufacturer itself, so it is important to collect information related to customer needs and the electrical performance of the customer's vehicle. Back to BDU, its main components are relays, fuses, pre-charge resistors, current collection components, copper bars, connectors and wiring harness assemblies, MSD (optional), BMS (optional), etc. In order to ensure the safety and stability of the vehicle operation, we need to simulate the actual current working conditions and operating environment of the vehicle, and then test the various functions of BDU such as over-current protection, overload protection, and long-term stability.

NGI provides professional testing solutions for BDU:
The test items can cover the tests of main parameter performance such as current condition simulation test, environmental aging load test, DC input over-current protection, DC input overload protection, etc. The high-power and high-performance DC power supply can power the distribution circuit and serve as the driving power supply for the relay. The multi-channel DC load plays the role of load simulation of the distribution circuit, and the temperature acquisition card (optional) can monitor the temperature of the device in real time. The overall test system can highly simulate the operating environment of the distribution circuit, and perform various current timing durability tests on the internal circuit of the BDU to verify its long-term stability. During the test process, the user can edit and import the current-time test sequence with one click, and can flexibly and quickly edit the test plan.

● Solution features

The test system can import the current-time test sequence in Excel format, can flexibly and quickly edit the test plan, has high stability, and can meet the different test requirements of BDU
◼The system is open-architecture and easy to expand, with highly integrated modular design, which can effectively save time and space in system construction
◼The hardware system has a wide power coverage range, meeting the test requirements of different power ranges
◼High-security design can form all-round protection for the circuit of the object under test, and there are very few test failures under the long test time
◼The software system is independently developed, with a high degree of automation, a friendly and convenient interface, and supports flexible expansion and high-level customization of software test functions