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Reliable HV on-board power supply validation for shorter development times and increased system stability

High Performance HV On Board Electrical System and Charging Validation for the Mobility and Industry of Tomorrow

Electrification is advancing rapidly – and with it, the demands placed on high‑voltage on‑board electrical systems, charging infrastructure and energy‑efficient operating strategies. Bertrandt offers a comprehensive portfolio of state‑of‑the‑art testing and validation methods that support vehicle manufacturers, suppliers and industrial partners alike.

From conventional charging tests and standards‑compliant communication testing through to highly realistic environmental simulations, we reliably safeguard the functionality, safety and service life of all HV components.

How do OEMs and system suppliers benefit from Bertrandt’s on board electrical system expertise?

  • Many years of expertise and comprehensive system understanding in on-board power supply testing
  • In‑depth know‑how of global norms and standards
  • Holistic test strategies for individual components and complete systems
  • Maximum transparency regarding functionality, service life and standards compliance
  • Flexible test centers, modernly equipped for all HV voltage ranges

Which components, modules and systems can Bertrandt test for you?

We test and validate, under realistic conditions, among others:

  • HV auxiliary units such as heaters or air‑conditioning compressors
  • HV connectors and complex wiring harnesses
  • Battery management systems including cell monitoring
  • Onboard chargers
  • AC/DC / DC/DC inverters
  • Charging inlets, charging cables and wallboxes / charging stations (AC/DC)
  • Inductive charging solutions (WPC)

How do we test the interaction between the vehicle (EV) and the charging infrastructure (EVSE)?

We use flexible test setups that support both real components and simulations:

  • Simulation of the vehicle or the charging station
  • Testing of real vehicles against real charging stations (man‑in‑the‑middle setup)
  • Testing of standards‑compliant communication according to DIN SPEC 70121 or ISO 15118

What role do environmental conditions play in safeguarding the HV on‑board power supply?

To validate the service life and robustness of all charging and HV components, we reproduce:

  • Temperature changes
  • Humidity exposure
  • Mechanical loads

Our measurement and automation technology ensures maximum information density and supports optimal development decisions.

How can we support you in your HV on‑board power supply project?

Whether validation of individual chargers, complete on‑board power supply architectures or project‑specific special test setups – we jointly develop the appropriate test strategy.

Inductive charging at Bertrandt

Inductive charging offers wireless convenience and high robustness in everyday use. It reduces wear on connectors and enables automated docking as well as weather‑independent energy transfer – ideal for fleets, parking garages or shuttle applications.

  • In‑process charging instead of charging islands: energy is recharged during already existing downtimes (e.g. loading/unloading, set‑up or buffer times) – fewer dedicated charging trips, higher availability.
  • Higher degree of automation: the handshake between vehicle and charging station can be fully integrated into control and automation technology.
  • Robust in harsh environments: smooth, closed surfaces without mechanical plug‑in cycles are less sensitive to dust, moisture and weather conditions – reducing fire and failure risks.

We combine functional and efficiency tests with environmental, robustness and misalignment testing. This includes thermal assessments, communication checks, safety functions (e.g. foreign object and living object detection) as well as analysis of real load and cycle profiles in your application – for reproducible and transferable results.

With inductive intermediate charging, unplanned downtimes are reduced; cycle times become more predictable, fleets can be dimensioned smaller, and battery capacity can be designed more demand‑oriented – improving utilization rates and total cost of ownership (TCO).

  • Transparent test execution with recording of all processes and communication events
  • Customer‑specific fault injection and real‑time evaluation of V2G/EVSE signals for fast root‑cause analysis
  • Interoperability and stress tests for chargers and vehicles – on site or in the laboratory
  • Clear KPI reports (e.g. charging energy per cycle, availability, efficiency) with recommendations for design and operation

Our HV test environments map relevant voltage ranges up to 1200 V – from individual components (e.g. OBC, inverter) to integrated system setups. This ensures realistic boundary conditions even for modern 800 V architectures.

Your Contact

Oliver Conrady

Vice President Operations

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