dSPACE OBC HIL Hardware Validation Solution: Full-Function On-Board Charger Real-Time Testing and Validation Platform
As electric vehicles move towards high-voltage architectures and V2G (Vehicle-to-Grid) bidirectional charging technologies, On-Board Chargers (OBC) not only see climbing power levels but must also be compatible with complex global charging standards and cybersecurity protocols. However, if tested directly using real charging stations and high-voltage batteries, actual vehicle/station tests not only struggle to cover all boundary conditions but also bring fatal safety risks like high-voltage arcs and battery thermal runaway.
Jotactic introduces the dSPACE OBC HIL hardware validation solution. We provide an integrated real-time testing bench from the 'signal level' to the 'power level', safely and efficiently digitally twinning the global power grid and multi-standard charging station behaviors in the laboratory, assisting R&D teams in achieving 24/7 high-performance closed-loop automated testing.
Core Mental Model: OBC HIL Closed-Loop Testing Principles
The core value of dSPACE OBC HIL lies in 'comprehensively simulating the OBC's external electrical and communication environment.' Through the highly reliable SCALEXIO real-time system, the bench can simultaneously simulate AC/DC grids, charging station Control Pilot (CP/PP) signals, and high-voltage traction batteries, forming a highly dynamic, deterministic closed loop with the OBC under test.
Dual Value Proposition: Signal Level and Power Level Validation
1. Signal-Level HIL (Signal-Level HIL)
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Implementation Method:
Simulates low-voltage control signals and communication protocols, while the power portion is replaced by virtual models or low-power hardware.
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Validation Focus:
Charging Handshake process, Control Pilot (Signal Duty Cycle) state switching, CAN/LIN restbus communication, and diagnostic logic.
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Main Value:
Low cost and high efficiency, suitable for early rapid iteration of software algorithms.
2. Power-Level HIL (Power-Level HIL)
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Implementation Method:
Integrates real high-power bidirectional AC/DC Grid Simulators and high-voltage DC electronic loads (Battery Simulators).
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Validation Focus:
OBC hardware overvoltage/overcurrent protection, high-frequency switching power characteristics, harmonic injection robustness, thermal management protection, and power quality during V2G inverter feedback to the grid.
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Main Value:
Complete coverage of electrical behavior, conducting the most stringent hardware-software co-safety tests before mass production.
Two Key Technologies
Key Technology 1: Smart Charging Multi-Standard Communication Validation
Global charging standard interoperability is the biggest challenge for OBCs. The dSPACE solution features a powerful built-in Smart Charging module capable of fully virtualizing communication controllers (EVSE) of charging stations worldwide:
Perfectly supports ISO 15118 (including Plug & Charge pre-loaded certificates), DIN SPEC 70121, GB/T 27930 (GB DC), and CHAdeMO.
Accurately generates and measures IEC 61851's +/-12V PWM Control Pilot (CP) and Proximity Pilot (PP) resistance states.
Can intentionally inject message delays, packet loss, CRC errors, or invalid certificates at specific state machine timing points (e.g., during TLS handshake or SDP request) to force tests of the OBC's abnormal termination mechanisms and fault tolerance.
Key Technical Highlight 2: Highly Dynamic Grid and High-Voltage Battery Simulation
In Power-Level HIL, the bench provides extreme fidelity of the electrical physical environment:
Supports single-phase/three-phase AC grids, providing not only stable voltage but also simulating severe global grid conditions such as voltage sags/dips, frequency drift, harmonic distortion, and surges.
Utilizes real-time physical model calculations to highly dynamically simulate the battery pack's Open-Circuit Voltage (OCV), dynamic internal resistance, and charge/discharge polarization effects, instantly responding to the OBC's charging current and providing the most realistic closed-loop load behavior.
Unified Toolchain and Test Automation Workflow
dSPACE provides a consistent workflow from pure software simulation (SIL) to real-time power integration (HIL), with models and test scripts being 100% reusable:
ConfigurationDesk & ModelDesk
Hardware I/O modeling and real-time code generation, with parameterized configuration of battery, grid, and power electronics models.
Add Sensors: Configure cameras, radars, lidars, and other sensors for the ego vehicle, setting installation positions and parameters.
VEOS
Pure PC-based SIL Virtual Validation ──> Shares the same models and scenarios with HIL
SCALEXIO Real-time Platform + Smart Charging GUI
Physical Bench Closed-Loop Integration Execution
ControlDesk
Measurement calibration, real-time parameter observation, and custom HMI dashboards
AutomationDesk
Charging scenario-based 24/7 automated batch testing and report generation
Scenario-Based Automated Testing and Consistent Regulatory Coverage
Scheduled via AutomationDesk, the system can traverse boundary and fault scenarios 24/7 unattended. The system also features built-in Conformance Test Suites for ISO 15118-4/-5 and DIN SPEC 70122, significantly shortening compliance testing cycles for OEMs or certification labs.
Three Core Benefits of Enterprise OBC HIL Implementation
Priceless Safety, Zero-Risk Validation
Simulates high-risk long-tail conditions such as real high-voltage/high-power electrical short circuits, insulation failures, grid overvoltage, and communication interruptions in a safe laboratory environment, ensuring the safety of engineers and equipment.
Drastically Reduces Test Hardware and O&M Costs
Eliminates the enormous expense of purchasing real charging stations from various countries and physical high-voltage batteries. Electrical parameters can be switched with one click—saving time, effort, and electricity costs.
Breakthrough Test Coverage and Determinism
A 100% reproducible and repeatable testing environment. Sporadic 'charge interruptions' or 'handshake failures' during road or station testing are difficult to capture; in the dSPACE HIL environment, all signal and message timings can be precisely controlled, making algorithm debugging accurate and efficient.