Electric vehicles need to function with different charging infrastructures worldwide. During vehicle development, Audi uses an innovative grid simulation realized with components from the automation system ctrlX AUTOMATION from Bosch Rexroth.
This solution enables the realistic simulation of power grids available worldwide and tests electric vehicles under various grid conditions. This ensures that Audi's vehicles can reliably operate at different High Power Charging (HPC) stations globally.
Grid simulation is necessary because grid configurations, voltage ranges, and frequencies vary from country to country. Audi chose a solution with Rexroth automation solutions that allows flexible simulation of foreign voltage grids based on globally available grid configurations and frequencies. The solution supports various grid types and voltage ranges from 100 to 540 V and frequencies from 40 to 65 Hz. It enables power up to 500 kW and supports single-phase, two-phase, and three-phase grids.
Power is provided by the mains power inverter IndraDrive ML and the isolating transformer. The control and monitoring of the system are handled by the compact control platform ctrlX CORE in combination with ctrlX I/O. The scalable ctrlX SAFETY ensures the safety of the system. An intuitive operation is guaranteed by the web-based HMI solution WebIQ and an external control terminal with ctrlX HMI.
Bosch Rexroth's solution impresses with its high flexibility and performance. The automation system ctrlX AUTOMATION offers an open, modular app-based architecture that allows adaptation to different grid configurations, voltages, and frequencies. Efficient heating and cooling technology ensure that the system operates optimally even in extreme outdoor temperatures. The grid simulation is housed in an insulated container solution equipped with a heat pump cooling system and a heater to enable outdoor operation.
The installation was carried out in collaboration with partner company Schmidbaur in the existing test charging park on the Audi plant premises in Ingolstadt.
"Thanks to the close collaboration with Bosch Rexroth and Schmidbaur, a tailor-made solution has been developed that meets both the technical requirements and the specific conditions of the site. The system is a scalable and thus future-proof solution to meet the challenges of electromobility," says Daniel Ettinger, Project Manager in the Testing Development Driving/Energy department at Audi.
Read the full case study on grid simulation in our new ctrlX AUTOMATION magazine and find out how your company can benefit from ctrlX AUTOMATION.
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