Electric Vehicle Charging Systems: Development and Testing

With more than 12 years’ experience, IDIADA is a world leader in prototype development and charging test activities, performing tests to ensure the interoperability of the interfaces of electric vehicles and charging stations, as well as the compliance of both interfaces with charging standards.

More than 35 charging experts and workshops in Spain, Germany, the US, and China support our clients worldwide.

Charging specification definition and training

Thanks to acquired know-how, IDIADA’s charging team can support in the definition electric vehicle charging architecture, prototyping and regulation compliance according to worldwide standards.

Additionally, customized training on the required charging topic can be given:

• IEC, SAE, CCS, GB/T, CHAdeMO and OCPP 1.6
• Upcoming concepts such as ChaoJi, ISO ed.20, PnC, OCPP 2.0.1, etc.

IDIADA has developed a CCS and NACS V2G decoder software that decodes and analyses the V2G Transport Protocol during charging sessions or for post-analysis. It comes as a plug-in for the most commonly used and known packet sniffer "WireShark", allowing to log and open pcap files.

You can find more information about our CCS and NACS V2G decoder software in our e-commerce platform, where you can purchase the tool by contacting our technical team to arrange a demo or request a quotation.

Certification and conformance testing

IDIADA was the first European CHAdeMO certification body and has increased the capability since then and is now an accredited laboratory by ENAC with the recognized International Standard ISO 17025 for:

• IEC 61851-1 – Requirements for conductive EV charging systems
• IEC 61851-23 – DC EV Charging systems up to 500kW
• IEC 61851-24 – Digital communications for EV charging systems

This accreditation demonstrates technical competence and a high-quality testing process, supporting the self-certification process of the CE Marking of our clients.

The conformance test is done against IDIADA’s simulator to ensure conformity of the EV or EVSE with the standards:

• At vehicle or component level
• Test up to 500kW DC power
• More than 800 test cases
• Automatic test analysis for fast and easy test performance
• All standards available: AC, CCS, GBT, CHAdeMO and OCPP
• Charging tests for DC and AC such as: induction of failures: insulation, cut of control signals, misuse tests, emergency shutdowns management, validations of the communication, power operation validation up to 500kW DC
• AC grid emulation with multiple grid conditions: harmonic disturbances, 50/60Hz, etc.

IDIADA’s charging simulator, also known as Multi Charging Test System is designed and used by our charging engineers. This brings a high flexibility during testing and allows the inclusion of all know-how into this tool. It is available at IDIADA’s facilities, but it can also be purchased/rented for self-development.

Performance tests at extreme temperatures are also available for development or benchmarking activities. Charges up to 500kW can be done inside a climatic chamber (-30°C up to 50°C) for checking charging performance, efficiency, power distribution etc., and vehicles/chargers can be instrumented if needed.

Charging Market Study

IDIADA has performed an in-depth analysis of the AC and DC charging stations installed at public places worldwide, identifying the brand and model of each, as well as the provider/network.

Data is regularly updated and provides:

• Market share numbers of the different charger manufacturers
• Market share numbers of the different charger models
• Market share numbers by country and/or regions
• Market share numbers by used charging protocol

Discover comprehensive details regarding our Charging Market Study on our e-commerce platform, where you have the option to procure the tool. Feel free to reach out to our technical team to schedule a demonstration or request a price quote.

Interoperability tests

The interoperability tests will be done against the most representative charging stations or electric vehicles. They consist of an in-depth analysis of the charge process when performing a high number of different tests cases in various stages of the charge process and checking in detail the communication and analog signals:

• More than 20 DC and 30 AC charging stations constantly available at IDIADA for this purpose
• New market vehicles available
• Exhaustive test list to ensure full interoperability
• Highly instrumented tests with non-invasive communication sniffers and specific interoperability test tools used for fast and safe data collection
• User abusive testing and error performance
• Experts and strong collaboration with EVSE manufacturers for root-cause analysis in case of incompatibilities

In-field tests

In-field tests or FOT consist of a final check to ensure compatibility with a wide range of charging station brands and models in real situations:

• Tailor-made routes in the target markets for maximizing coverage
• Technical data collection and analysis for all charge processes
• Test under different grid conditions
• Test performance by experts for in-field problem-solving

Charging facilities

Headquarters & Technical Centre - Pol. Industrial L'Albornar, 43710 Santa Oliva, Tarragona, Spain

• 4 slots for light vehicles
• 2 slots for heavy-duty vehicles
• 15 sockets 5 pins 32A
• 4 sockets 5 pins 125A
• 1 socket 5 pins 250A
• 1MW AC Grid capability
• Battery simulator up to 500kW
• 40 kVA Grid emulator
• ACD Pantograph systems (up and down)
• High Power CCS connector for non-ACD buses
• 2 climatic chambers (from -30ºC up to 50ºC) with charging ability up to 500kW
• 20 DC and 30 AC different charging stations for testing
• Charging test tools available:
  • Breakout boxes (AC type 2, AC type 1, CCS2, CCS1 and CHAdeMO)
  • Oscilloscopes
  • PLC analysers
  • CAN loggers
  • INCA loggers
  • EV/EVSE emulators (AC, CCS, CHAdeMO, GB/T and ACD emulator) – MCTS

Applus+ IDIADA China - Jucheng Pioneer Park, Building 23, 3999 Xiupu Road, Kangqiao Town, Pudong District, 201315 Shanghai, China

• 400A 3 phase 5 pin socket
• 250A 3 phase 5 pin socket
• 200A 3 phase 5 pin socket
• 125A 3 phase 5 pin socket
• 2 63A 3 phase 5 pin sockets
• 2 32A 1 and 3 phase 5 pin sockets
• 16A 1 and 3 phase 5 pin socket
• 200kW AC Grid capability
• Battery simulator 150kW
• 1 climatic chamber (from -40ºC to 60ºC) with charging ability up to 160kW
• Charging stations for testing:
  • 24 GB/T DC and 17 GB/T AC
  • 2 CCS1 DC and 4 Type 1 AC
  • 1 CCS2 DC charger 3 Type 2 AC

• Charging test tools available:
  • Breakout boxes (GB/T DC, GB/T AC, CCS2)
  • Oscilloscopes
  • PLC analysers
  • CAN loggers
  • INCA loggers
  • EV/EVSE emulators (GB/T, CCS2, CHAdeMO) – MCTS

IDIADA Automotive Technology USA – LLC, 9121 Pulsar Ct., Corona, CA 92883, United States of America

• 1 dedicated charging slot and more available under request
• 1 socket 5 wires 480/277V 400A
• 1 socket 5 pins 480/277V 100A
• 1 socket 5 pins 480/277V 60A
• 1 socket 3 pins 208V 60A
• 1 socket 3 pins 208V 50A (NEMA 6-50)
• 2 socket 3 pins 120V 20A (NEMA 5-20)
• AC and DC charging stations available for testing
• Charging test tools available:
  • Break out boxes (AC type 1, CCS1)
  • Oscilloscopes
  • PLC analysers
  • CAN loggers
  • EV/EVSE simulator up to 30kW (CCS1, CCS2, SAE AC, IEC AC*, NACS coming soon) – MCTS

IDIADA Fahrzeugtechnik GmbH -  Manchingerstraße 97, 85053 Ingolstadt, Germany

• 2 slots for light vehicles
• 2 sockets 5 pins 32A
• 4 sockets 5 pins 16A
• 1 climatic chamber (from -30°C to 50°C)
• DC charging stations for testing up to 350kW
• Charging test tools available:
  • Oscilloscopes
  • PLC analysers
  • CAN loggers
  • EV/EVSE emulator (AC, CCS, CHAdeMO and GB/T) – MCTS