As the electric vehicle (EV) market continues to accelerate, automakers are racing to introduce more efficient and eco-friendly models to secure their competitive edge. At the heart of this competition lies the battery—a critical component directly impacting mileage, safety, and overall user experience. To optimize battery development, tech companies are increasingly adopting virtual vehicle models. By creating vehicle simulations that accurately replicate EV operating conditions, R&D teams can get a comprehensive grasp of the performance of their battery packs across diverse environments using a laboratory test bench. This enables developers to anticipate and address potential issues at the design stage, minimizing the need for costly reworks and in turn driving down development costs and time to market.
Chroma has partnered with Altair, a global leader in computational intelligence, and Tron Energy to launch an advanced dynamic battery charge-discharge testing collaboration. This project aims to enable verification and enhancement of battery performance and lifespan through leading-edge equipment and precise simulation technology. It integrates Chroma’s Battery Pack Power Hardware-in-the-Loop (HIL) system, Altair’s precisely designed vehicle dynamics and battery models, and Tron Energy’s real bus operational data to simulate the driving conditions of Tron Energy’s electric buses on a test bench, facilitating repeated dynamic charge-discharge and cycling tests.
The following graph shows test results that include vehicle speed, motor speed and torque, and battery current. It demonstrates a high correlation between the real operational data of a Tron Energy e-bus and the simulated battery charge-discharge and motor output data using Chroma’s Power HIL equipment. This attests to the accuracy and feasibility of the testing method. The overall results not only validate the reliability of Chroma’s test system and Altair models but also provide valuable data to support vehicle development, helping to enhance battery life and performance.
Chroma ATE has recently introduced the Chroma 8610 Battery Pack Power Hardware-in-the-Loop (HIL) Test System. In addition to performing traditional signal control tests, it also covers validation of actual power behavior. Compared to conventional signal-level HIL solutions, the 8610 provides more comprehensive testing coverage for high-power EV components. It enables users to validate battery packs, battery modules, battery management systems (BMS), and thermal management systems on the right side of the V-model development process. These validations include complex battery pack system-level functionality tests, helping to detect and fix problems early before whole vehicle testing, effectively reducing development costs and improving testing efficiency.
When paired with a Chroma 170X0 Series battery charge-discharge system, the 8610 can simulate dynamic load and regenerative behaviors for battery packs within the power system. It also supports the integration of Altair® Twin Activate® vehicle models and various real-time mathematical models based on Simulink®. The system facilitates validation of dynamic charge-discharge performance for entire vehicles under driving conditions stipulated in international standards like NEDC and WLTP.
As an established leader in the field of electric buses, Tron Energy is committed to applying innovative technologies to enhance product competitiveness. It is trusted for its excellent performance, efficiency, and modern features that enhance passenger comfort. Altair provides software and cloud solutions in simulation, high-performance computing (HPC), and artificial intelligence (AI). Its advanced simulation software is widely used in the automotive, aerospace, and energy industries. With its powerful vehicle modeling technology, Altair offers accurate data simulation and analysis that helps optimize vehicle design and performance.
More About Chroma 8610 Battery Pack Power HIL Test Bed
Learn more about Altair® Twin Activate™ in the Altair HyperWorks design and simulation platform: Altair® Twin Activate™
Learn more about Tron Energy’s electric vehicles and energy storage systems: Tron Energy Electric Vehicles and Energy Storage Systems