Starter / Alternator Test

Power units for the starter battery, starter motor and electric system

The first electric starter motor was invented back in 1899 by Clyde J. Coleman. However it was only later models that were truly functional. Today, the starter motor is one of the most important components in the car. As an auxiliary assembly for starting combustion engines, it must always function reliably, even in extreme temperatures and environmental conditions.

Heinzinger electronic GmbH has developed power units especially for the validation of these components that are able to precisely map the characteristics of a starter battery. These devices are available in voltage ranges from 6 V to 65 V, thereby covering the entire bandwidth of all types of battery used. With currents from 1,500 A to 10,000 A, even high-powered assemblies can be tested.

Robust power supply needed

In this sector, power supply units based on the linear regulator principle are therefore state of the art. They can be used on testing rigs in development and quality laboratories, as well as in test set-ups on production lines for components and assemblies, right through to testing rigs for complete vehicle tests.

Under arduous environmental conditions especially, such as the ones found in climate chambers, for example, devices with linear regulation have been used for years with tremendous reliability thanks to their robust structure and superb precision. These devices are also problem-free energy providers in the context of EMC-sensitive environments (EMC measuring chambers, etc.).

High-precision technology for maximum accuracy

Superlative precision delivers reproducible results. Various power unit concepts are needed, depending on the area of application. Dual-stabilized power units with linear regulation satisfy the most exacting demands in terms of accuracy and stability. With these high-precision power units, accuracy classes of between 0.001% and 0.01% are achieved. For comparison, single-stabilized power units have an accuracy of 0.1% with low dynamics. 16 V, 32 V or even 65 V power units are typically used as battery substitutes, for example. This means that the conventional battery voltages of 12 V and 24 V can be covered just as easily as applications in the 48 V electric system sector.

The relevance of 48 V electric systems is increased further by the use of micro- and mild-hybrid systems. This requires not only new components and modules, but also new requirements in relation to testing systems. The new ERS Compact from Heinzinger has been designed especially for these test requirements.

Realistic simulation of driving cycles

In addition to the typical performance data such as current and voltage, short-term overload capability and the dynamism of battery simulators also play a central role when driving cycles are to be mapped in realistic terms. Both aspects are combined in the new ERS Compact, making it the ideal bidirectional power supply for low-voltage applications. The ERS Compact has a continuous output of 20 kW and is able to deliver a maximum output of 30 kW and an impulse current of up to 500 A.

Modular structure for flexibility

Another advantage is the modular structure, which allows the connection of up to four devices in serial, parallel and mixed configurations. An almost limitless combination of voltages and currents can also be created. They also have the option of easily expanding the test setup with a further system at a later point in time.

Tracking of driving cycles in real time

By using the latest FPGA and SiC technology, a rise time for voltage and current can be achieved of well below 1 ms. This means that driving cycles can be tracked in real time. As a positive side effect of the latest SiC technology, the efficiency of the ERS Compact increases to a remarkable > 97%, saving additional energy.

Intuitive operation, interfaces for combination with other systems

The intuitive touch panel, combined with the test sequencer, scope and measuring function, supports the demands made on a “standalone” unit. For use as a sub-system in a superordinate testing environment from development to series production, the ERS Compact provides numerous interfaces such as CAN or Ethernet.

We would be delighted to advise you on choosing the right power unit for your applications. Call us on +49 8031 2458 0 or send an e-mail to info(at)heinzinger(dot)de

The following products can be used for these applications

ERS

 DC Sources / Sinks for Testing Rigs

PTN

Low-voltage power supplies with double-stabilization and linear-control

GEN

Variable power supplies for integration into systems where space is scarce in the DC area