Conventional propulsion systems and the infrastructure are only loosely connected, while plug-in electrified vehicles are strongly connected to the infrastructure. New standards and norms regarding connections, communication, safety, etc. had to be established between OEMs and the industry in recent years. It is desirable to move charging test activities to a controlled test environment to reduce test costs, accelerate development, improve V&V, and enhance quality and customer experience.
Simulated charging enables testing of various communication protocols as well as misuse or failures/malfunctions of charging stations. For AC charging, different mains supplies can be tested depending on the region, e.g. JP, US and EU.
The central component of the Test System is the AVL Universal Charger™. It plays a crucial role in evaluating charging communication performance, ensuring the accuracy and reliability of test results. It is designed to provide comprehensive interoperability and conformance testing for electric vehicle charging systems.
The AVL Universal Charger™ is an AC/DC charging test solution designed to address global communication standards like CCS, GB/T, etc., it enables EV charging validation in a unified system. It supports high-power charging, manipulations like fault injection, edge-case reproducibility and automation via AVL PUMA™.
The continuous software evolution and AVL PUMA integration enable reproducible and automated testing, while reducing cost, complexity, and validation risk.
The AVL Universal Charger accelerates vehicle charging system development and improves the end-customer experience at the public charging station by increasing EV-System interoperability.
The system validates charging communication across all major global standards by simulating faults, injecting errors, and manipulating polarity to observe and assess system response under varied conditions. This enables all kind of electric vehicles to meet the highest levels of reliability and performance.
| DC Charging Interfaces | |
| CCS-1 | Max. 1,000 V DC, max. 800 A, active cooling |
| CCS-2 | Max. 1,000 V DC, max. 800 A, active cooling |
| NACS (upcoming)* | 1,000 V DC, 600 A cont. / 800 A peak |
| CHAdeMO | Max. 1,000 V DC, max. 200 A, passively cooled |
| GB/T | Max. 1,000 V DC, max. 250 A, active cooling |
| AC Charging Interfaces | |
| Type-1 | 240 V AC, 32 A (grid emulation option) |
| Type-2 | 480 V AC, 32 A |
| GB/T | 440 V AC, 32 A (grid emulation option |
| NACS (upcoming)* | 240 V AC, 32 A (grid emulation option) 240 V AC, 80 A (grid emulation and NACS extension unit) |
| * Planned functionality not currently available. Specifications and release dates are subject to change. | |
Up to 20% reduction of development time
when used in a fully-automated High-Voltage Compound Testbed (HVV). Capabilities allow to fix real-world charging issues before vehicles reach the maturity for field trials, saving considerable development time
“All-in-one” integrated Charging Test System
The AVL Universal Charger consolidates AC and DC charging into a single device covering CCS1/2, CHAdeMO, GB/T, with NACS availability planned (Q1 2027).
User-friendly end-customer experience at the charging station
by using the V2H/V2G capabilities customers can further develop solutions for a user-friendly charging experience at home.
Greater Convenience and Testbed Efficiency
the software automation AVL PUMA contains all main global standards in one housing, reducing the necessary footprint in the testbed when operating a variety of charging testing devices.
Continuous Software Evolution
The software driven AVL Universal Charger™ stays aligned with officially released charging standards through continuous feature, version updates and bug fixes.
Easy and cost-efficient retrofit of AVL testbeds
integrating the AVL Universal Charger is a straightforward and highly cost-effective retrofit for high-power charging applications and emerging test use cases.
Flexible Interoperability Testing
The communication between charging station and vehicle can be analyzed and tested. By offering configurable manipulation users can execute interoperability tests for their specific challenges.
High Power and Bi-Directional Charging
Our powerful AVL E-STORAGE not only enables supply over the entire range (voltage, current, power) of charging applications, but is also prepared for the increasingly important bidirectional testing.
Grid Emulation
The use of a grid emulator makes it possible to test different power supplies and their behaviour by region, e.g. JP, US and EU. With this tool it is also possible to emulate phase failures and frequency fluctuations, like LVRT, HVRT, Frequency Sweep, Phase Imabalance, Power Quality/THD. These tests are crucial for grid stability, safety, and certification especially for V2G-capable chargers.
Highly Automatable
Specific load test packages can be executed automatically with the test system. It is also possible to simulate the plugging process of the charging connector.
AVL E-Mobility Testing Solutions – Brochure
Tested and Trusted.
AVL Vehicle Charging TS™ – Solution Sheet
Fast development and validation of electric drives.
AVL Universal Charger™ - Solution Sheet
Find out more on the capabilities of the Universal Charger - from component validation to communication testing and beyond.
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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.