Automotive Manufacturing - Development of a Portable Multi-Standard EV Charging Test System
As electric vehicle adoption accelerates, automotive OEMs face growing pressure to validate charging interoperability across multiple standards, including CCS, CHAdeMO, GB/T, and NACS. Most manufacturing plants still depend on bulky, stationary test benches that require high-power infrastructure and typically support only limited protocols. This often leads to incomplete end-of-line validation, delayed detection of communication or safety defects, and increased risk of costly field failures. Issues such as PLC timing mismatches, HVIL wiring faults, and precharge inconsistencies frequently surface only after vehicles reach customers, underscoring the need for a comprehensive and portable validation solution.
Pi Square Technologies addressed this challenge by developing a portable, multi-standard EV charging test system delivering up to 30 kW DC and 21 kW AC power, designed for rapid end-of-line validation. Mounted on a rugged industrial cart, the solution integrates modular power electronics, universal communication stacks, and a quick-swap connector system supporting CCS, CHAdeMO, GB/T, and NACS. A fully automated 120-second test workflow validates safety checks, protocol handshakes, precharge behavior, current ramps, and fault handling, supported by advanced safety features and integrated protocol logging with MES traceability.
The solution delivered measurable operational and quality improvements by consolidating multiple test benches into a single mobile platform, significantly reducing equipment footprint and eliminating the need for high-power infrastructure at every station. Automated, repeatable testing aligned with assembly-line takt times reduced operator dependency while enabling early detection of communication and power-transfer issues. Its portability allows flexible deployment across production lines, R&D labs, supplier sites, and service centers, providing OEMs with a unified, scalable, and future-ready platform for global charging interoperability testing.