BOLAB ISO 21498 HV Test System & Ripple Generator
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| Sec | Test | Test Parameters | Voltage Levels | Frequency Range | Operating Conditions |
| 5.2 | DC Supply Voltage Variation | Voltage variation within operational limits; Rates 2V/s; Hold ≥ 30s | Ulower_limit to Uupper_limit | DC only | Continuous operation, unlimited range |
| 5.3 | Generated Voltage Slope | Voltage slope rate; Peak power transitions; Frequency ≤ 1 kHz | Within an unlimited operating range | DC transitions | Peak/idle power transitions |
| 5.4 | Immunity to Voltage Slope | Voltage slope immunity; Rates ≥ 1, 10, 20 V/ms; OS stability | OS1 and OS2 ranges | DC transitions | Stable operation during voltage slopes |
| 5.5 | Generated Voltage Ripple | Ripple voltage measurement; 10 Hz to 150 kHz; ≤ 5% tolerance | Uinit, Umax_unlimited_op, Umin_unlimited_op | 10 Hz - 150 kHz | Worst-case ripple conditions |
| 5.6 | Immunity to Voltage Ripple | Ripple immunity; Frequency sweep 10 Hz -150 kHz; Sinusoidal ripple voltage | Uupper_limit, Uinit, Ulower_limit | 10 Hz - 150 kHz (sinusoidal) | Ripple tolerance under load conditions |
| 5.7 | Overvoltage | Overvoltage tolerance; Upper voltage limit; ≤ 2 V/s rate; Hold time ≥ 10 s | Above Uupper_limit to Uover_limit | DC | Component protection mode (OS3, OS4) |
| 5.8 | Undervoltage | Undervoltage tolerance; Lower voltage limit; ≤ 2 V/s rate; Hold time ≥ 20 s | Below Ulower_limit | DC | Stable under voltage drops; OS3, OS4 |
| 5.9 | Voltage Offset | Offset voltage handling; Connection of HV+/HV- to ground reference; ≤2 V/s rate | Offset to ground reference | DC | Stable with offset conditions |
| 5.1 | Generated Load Dump Voltage | Load dump voltage generation; Power disruption; Peak voltage and rise time measurement | Generated by DUT, measured at disruption | Transient DC | Generated load dump event |
| 5.11 | Immunity to Load Dump Voltage | Load dump voltage immunity, Rapid voltage rise, Voltage level up to overvoltage limit | Up to Uover_limit | Transient DC | Stable under load dump voltage conditions |
Unique Series Amplifier Integration
Unlike conventional ripple test setups, BOLAB's revolutionary design places the amplifier directly in series with the HV power supply, ensuring:
- Superior Test Accuracy: Eliminates signal distortion, providing accurate ripple injection across all frequencies.
- Increased Efficiency: Minimizes power loss and maximizes test energy delivered to the Device Under Test (DUT).
- Enhanced Safety: Advanced coupling methods safeguard both personnel and equipment by effectively isolating and controlling high-voltage signals.
High Speed
Even Load Dump pulses are covered with BOLAB´s, unique in the world, high-end test systems for Electric Vehicles.
3000 V/ms for 20 V is required in VW80300 with a 7µs rising time.
BOLAB´s solution: better than 1µs!
250 V/ms increase for 150 V:
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| HV supply | High Frequency 4 Quadernt Supply | Combination in series |
High Voltage DC Power Supply + 4 Quadrant Amplifier In Series
Setup
As coupling network transformers (CDN) are limited in speed, frequency ranges, amplitude and especially allow only sine interferences, this solution cannot be used for Load Dump applications. Load Dump requirements are both part of LV 123 and VW 80300 standards.
Our most flexible solution is the combination of a high voltage power supply in series to our 4 quadrant amplifiers. Individual transients and even Load Dump requirements are possible.
In addition, BOLAB’s modular design allows the adaption to almost all manufacturers of high voltage power supplies. There is no need to purchase an additional power supply if one is already available.
Advantages
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Comprehensive Testing Capabilities
The BOLAB HV Ripple Generator effortlessly meets and exceeds the stringent requirements outlined in ISO 21498 and other critical automotive standards:
- Frequency Range: 10 Hz to over 300 kHz
- Ripple Voltage: Up to 100 V peak-to-peak (Vpp)
- Ripple Current: Scalable from 100A up to 2000A+ Upgrade onsite
- Injected Waveform Versatility: Sine, square, trapezoidal, pulses, and triangle waveforms
Industry-Leading WaveMaster Software
BOLAB's WaveMaster software transforms your testing environment:
- Rapid DUT Impedance Measurement: Accurately measure impedance in under one minute.
- Real-Time DAQ Integration: Continuously monitor DUT performance and instantly adapt test parameters.
- Automated Test Sequences: Simplify complex routines with fully customizable and repeatable test sequences.
- Dynamic Compensation: Automatically adjusts voltage and current to maintain consistent test conditions, even at challenging high-frequency and low-impedance scenarios.
Built for Today, Ready for Tomorrow
BOLAB Systems ensures your testing solutions remain ahead of the curve:
- Future-Proof Design: Easily upgradeable hardware and software to accommodate evolving automotive standards.
- Robust Construction: Engineered for intensive use in industrial environments, providing long-term reliability and consistent performance.
- Extensive Standards Coverage: Compatible with ISO 21498, ISO 7637-4, LV123, VW 80300, Nissan MES PW 67602, Mazda, BMW GS 95023, Renault 36-00-811, and more.
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