The on-board power assembly is the core "energy hub" of an electric vehicle, integrating three key components: the on-board charger (OBC), the DC/DC converter, and the high-voltage distribution box (PDU). It can be designed as an independent unit or a two-in-one/three-in-one/multi-in-one integrated unit according to application requirements. As the core module of the vehicle's "electronic control assembly", it undertakes the core functions of electric energy conversion, transmission, and management between the external power grid and the battery power supply, the high-voltage system and the low-voltage system. It directly determines the charging speed, power efficiency, and operational stability of the electric vehicle. Product reliability is also an important guarantee for the safety and core performance of the entire vehicle. Therefore, conducting accelerated durability and lifespan tests on the on-board power assembly during the finished product stage is a key section for product quality verification, and professional aging testing equipment is the core technical support for this process.
The CPET new energy vehicle power supply assembly temperature control liquid cooling integrated aging test intelligent equipment is specially developed and designed for vehicle power supply assemblies (three-in-one/multi-in-one). It can conduct long-term aging, reliability verification, thermal management matching, and extreme condition simulation tests. It precisely resolves the industry pain points of traditional air-cooling aging equipment, such as uneven temperature distribution, low temperature control accuracy, insufficient heat dissipation capacity, and inability to replicate the actual vehicle liquid cooling conditions. It provides professional and efficient testing solutions for improving the reliability of vehicle power supply assembly products.
This equipment simulates, accelerates and strengthens the electrical, thermal, mechanical and environmental combined stresses that the on-board power assembly may encounter during actual use. It can expose the potential design flaws, performance degradation patterns and failure modes of the product in a much shorter period of time than the actual product lifespan. This provides scientific and precise experimental data basis for product design optimization, process improvement and reliability enhancement.
The equipment adopts the core working logic of "maximum power pressure loading + liquid cooling temperature control cycle + ultra-high temperature ambient temperature control + multi-parameter full-dimensional monitoring + intelligent closed-loop collaborative control" to accurately replicate the real working scenarios of the on-board power assembly. The core working principle is as follows:
When the tested on-board power assembly operates continuously under full power or variable power conditions, the internal OBC, DC/DC power components, inductors, capacitors and other core components will generate a large amount of heat loss. The equipment uses a dedicated liquid cooling circuit to precisely deliver the coolant to the internal flow channels of the power assembly, forcing the heat generated to be discharged, and through precise temperature control technology, stabilizes the temperature of the core components at the set range of 85℃ to 125℃.
At the same time, the system simultaneously collects key parameters such as temperature, flow rate, pressure, voltage, current, efficiency, insulation, etc. from all dimensions, and feeds them back to the central control unit in real time. It dynamically adjusts the cooling efficiency of the liquid cooling system and the intensity of power loading, establishing a "thermal-electric-fluid" multi-closed-loop collaborative control system. It precisely simulates extreme working conditions such as high and low temperature cycles, thermal shock, continuous full load, and start-stop shock of the entire vehicle, achieving efficient acceleration of the product aging process and precise exposure of early failure issues.
To achieve high-precision replication of the actual temperature conditions of the entire vehicle, the equipment is equipped with two core temperature control units: the liquid cooling temperature control circulation system and the ambient temperature control circulation system. It integrates the classic PID control algorithm and the AI intelligent algorithm to construct the temperature control logic. It can flexibly adjust according to the testing requirements and efficiently reproduce the temperature environment of the vehicle power supply assembly in the actual operation of the entire vehicle, ensuring the authenticity and accuracy of the testing scenario.
The equipment is equipped with a complete extreme power pressure loading system, which can fully replicate the actual power environment of the product's operation: The AC input end can provide 220V/380V three-phase/single-phase AC power supply, accurately simulating the actual input scenarios of household sockets and public AC charging piles, supporting ±20% voltage fluctuation, frequency fluctuation and harmonic injection, and capable of reproducing abnormal working conditions such as unstable grid voltage and harmonic interference; The DC high-voltage end can output a 300V~1200V high-voltage DC source, accurately simulating different working states of power batteries such as full charge, depleted charge, and dynamic voltage, supporting voltage step changes and ripple superimposition, and covering all kinds of power working scenarios of the vehicle power system during vehicle operation.
At the same time, the equipment is equipped with a high-performance multi-parameter monitoring and data acquisition system, which enables precise capture, efficient storage and intelligent management of all-dimensional data during the testing process. It can complete the detection and precise control of ambient temperature, as well as the detection of flow, pressure, liquid level, medium temperature and leakage status of the liquid path system, high-precision detection of electrical parameters such as voltage, current, power, insulation resistance, leakage current, etc., and full-dimensional detection of product functions including OBC charging status, DC/DC output voltage stabilization performance, PDU on-off and protection functions, CAN/LIN communication status, and fault code reading. The system supports high-speed data acquisition with customizable sampling frequency, enabling local secure storage of aging test data, and also supports seamless connection with the enterprise MES system for data cloud upload. It has functions such as viewing of test history curves, automatic generation of aging test reports, and intelligent analysis of product failure modes, providing comprehensive and precise data support for product design optimization and process improvement.
Intelligent control and all-scenario security protection are the core competitive advantages of this device: The system adopts a highly stable architecture of industrial PLC + upper computer software, is equipped with professional aging test software for computer monitoring, supports users to customize the aging test process, can flexibly set key parameters such as aging duration, power curve, temperature curve, and cycle times, and realizes the automatic and intelligent multi-closed-loop collaborative control of the "power loading → heat generation → liquid cooling cooling → temperature feedback → dynamic adjustment of loading/cooling" test process flow.
In terms of safety protection, the system adopts a comprehensive scenario-enhanced design. It can respond quickly within milliseconds and trigger emergency shutdown protection for various abnormal situations that may occur during the equipment operation, such as overheating, overvoltage, overcurrent, undervoltage, leakage in the liquid path, insulation failure, etc., ensuring the safety of the testing equipment and the tested products. At the same time, the equipment supports multiple industrial communication methods such as CAN3.0, CANFD, RS485, and TCP/IP, enabling remote real-time monitoring of the testing process and full-process traceability of the test data, significantly improving the efficiency and operational convenience of aging tests.
In summary, the CPET Zhongyuan New Energy Vehicle Power Supply Assembly Temperature Control Liquid Cooling Integrated Aging Test Intelligent Equipment is essentially a professional reliability verification platform for vehicle power supply assemblies, integrating time acceleration and pressure simulation. It achieves "short-term advance" of product service life in the laboratory environment through precise multi-physical field coupling control and accelerated stress technology. It compresses the risks of vehicle power supply assembly usage on the road for months or even years into a few days, enabling early detection and resolution, providing crucial engineering technical support for enhancing the reliability and safety of new energy electric vehicles. At the same time, it also provides core technical support for the rapid iterative upgrade and continuous quality improvement of vehicle power supply assembly products.
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