AVL HV System TS™ E-Integration

Electric vehicle supply equipment (EVSE) as key technology in transition to e-mobility.

AVL HV System TS™ refers to the integration of high-voltage components of an electric vehicles. This includes components such as battery management systems, inverters, and electric motors, heaters etc.


The development of high voltage (HV) systems for electric and hybrid vehicles requires rigorous testing and validation to ensure safety and reliability. The HV system testbed is a specialized facility designed for this purpose, providing a controlled environment to evaluate the performance and behavior of HV systems under various conditions. The HV system testbed typically includes a range of testing equipment and instruments, such as battery simulators, motor generators, and power analyzers. These tools allow engineers to simulate different scenarios and test the HV system's response to different loads, temperatures, and voltage levels. In addition to performance testing, the HV system testbed is also used for safety testing to ensure that the HV system meets regulatory standards for electrical safety. This includes testing for insulation resistance, high voltage leakage, and short circuit protection.

HV systems are complex and dangerous if not properly designed and tested. The AVL HV System testbed provides a safe environment to test HV systems, which helps to prevent accidents and injuries. Besides that, cost-effectiveness is very important. Testing HV systems in a real-world environment can be expensive, time-consuming, and risky. The AVL HV System testbed provides a cost-effective way to test HV systems before they are implemented in vehicles, which can help to reduce development time and costs.

In general, HV systems need to be reliable and robust to ensure the safety of passengers and drivers. The AVL HV System testbed allows engineers to evaluate the reliability of HV systems under different conditions and scenarios, which helps to identify potential problems and improve the overall quality of the system. And also lexibility, as the AVL HV System testbed is highly flexible. With it you can react to the different version pattern phases in hardware development quickly as well as to new software versions during software development. In summary, an AVL HV System testbed is essential for E-Integration tasks as it provides a safe, cost-effective, reliable, and flexible environment for testing and validating high-voltage electric systems.


Consistent performance result under a variety of operating conditions.


Reduce risk for personnel and equipment with a special HV system integration testbed.


Streamline the testing process and reduce the time and effort in testing.


Consistent test conditions allow repeatable tests to identify problems with the charging infrastructure.

Cost Savings

Early detection of problems avoids downtime and replacement of costly HV systems.


The specifications of a High Voltage (HV) System E-Integration testbed can vary depending on the specific application and requirements of the test. However, here are some typical specifications that may be considered. It's worth noting that these specifications are just an example and can vary depending on the specific requirements and intended applications of the HV System E-integration testbed. The actual product specifications will depend on various factors, such as the types of electrical components to be tested, the voltage and current ranges, and the specific testing requirements.

Power capacity

Power capacity of the HV System E-Integration testbed should be sufficient to test high-power electrical components and systems. Typically, this would be in the range of 500 kW to 1 MW, although larger or smaller systems may be required depending on the application.
Voltage rating Voltage rating of the HV System E-Integration testbed will depend on the specific application and the voltage range of the electrical components being tested. However, typical testbeds would be capable of generating voltages in the range of 1000V to 1500V.
Current rating Current rating of the HV System E-Integration testbed will depend on the specific application and the current range of the electrical components being tested. However, typical testbeds would be capable of handling currents in the range of 500A to 1000A.
Sample rate Sample rate of the HV System E-Integration testbed will depend on the specific requirements of the test. However, typical testbeds would have a sample rate of at least 10 kHz, with higher sample rates available for more demanding applications.


Improved Reliability and Safety

Testing components and systems in a controlled environment can help identify potential issues and improve their performance, reliability, and safety.

Reduced Development Time and Cost

Reduce development time and costs as issues can be addressed early in the development process.

Simulation of Real-World Scenarios

By simulating e.g. short circuits, overloads, faults, and load fluctuations, test engineers can evaluate the performance of electrical components and systems under various operating conditions to improve their reliability and performance in the field.

Customization and Flexibility

Test engineers can adjust the test parameters, test scenarios, and other testing conditions to test the electrical components and systems under various operating conditions, allowing for greater flexibility in testing.

The High Voltage (HV) System E-Integration testbed is a facility used to test and validate the integration of various HV components in electric vehicles or other HV systems. Here are some features of the HV System E-Integration testbed:

HV-System Testing

The testbed allows for the individual testing of various HV components such as batteries, electric motors, power electronics, and other related components in their predetermined System.

System Integration

The testbed enables the integration of all HV components and their interaction with other vehicle systems such as the cooling system.

Real-World Simulation

The testbed can simulate real-world scenarios and environmental conditions (e.g., temperature and humidity).

Data Acquisition

The testbed is equipped with various sensors and data acquisition systems that can collect and analyze data related to HV component performance, system efficiency, and energy consumption.


The HV System E-Integration testbed is designed with safety measures such as protective shields, emergency stop switches, and electrical interlocks to ensure the safety of test personnel and prevent damage to HV components.


The testbed is flexible and can be reconfigured to accommodate different HV system designs and test requirements.

helmut richter

The HV system testbed is a critical tool for the development and validation of high voltage systems. It enables engineers to optimize system performance and safety before deployment in real-world applications.

– Helmut Richter, System Line Manager, AVL List GmbH

AVL E-Mobility Testing Solutions – Brochure

Tested and Trusted.

AVL HV System TS™ E-Integration – Solution Sheet

Fast development and validation of electric drives.

AVL Battery Test Systems – Solution Sheet

Designed to measure all important battery data at differing temperature and humidity.

rendering of charging car
AVL Vehicle Charging TS™

In addition to the on-board charger and the battery itself, most control units are also involved in charging the battery. With increasingly connected vehicles, the vehicle will need to communicate with many different types of charging stations and, in the near future, even directly with the power grid (for load balancing).


Battery tester and emulator for research and development, testing and validation.

X-ion e-power
AVL X-ion e-Power

The AVL X-ion™ e-Power power analyzer is a modular data acquisition platform that is optimized for electric and hybrid applications.


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