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Lab zone 5 of 6

Charging emulator

Run charging sessions, inject faults and measure losses, without high-voltage risk.

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EV charging emulator panel with display, energy meter and charging connector
Zone videoVideo to be added. Set its path in js/config.js.
Why it matters

The significance of this zone.

Charging is where the battery, the BMS and the grid meet. Real chargers are high power and unforgiving. This zone emulates a battery pack so students can run charging sessions, inject faults and measure losses safely.

Students see how voltage rises, how current tapers and how state of charge is estimated during a charge.

What you can do

Design custom charging curves

Compare CC, CV and CC-CV charging

Inject faults such as over-voltage and lost communication

Measure charge efficiency and power loss

Experiments

What students can run here.

Charging profiles

  • Constant current, constant voltage and CC-CV charging
  • Dynamic charging with time-of-day and grid-signal simulation
  • Multi-step automated charge sequences

Connector standards

  • Type 2 (Mennekes), the global standard
  • Bharat AC-001, the Indian standard
  • Connector and protocol comparison

Efficiency and analysis

  • Charge efficiency
  • Coulombic efficiency
  • Power loss with an energy meter
  • Validate a SOC estimation algorithm

Safety and fault testing

  • Over-voltage and under-voltage protection
  • Over-current limit response
  • Plug-out during a charge
Photos

Equipment and setup.

Charging emulator on its bench with keyboard and connector
Charging emulator on the bench

Equipment available

  • Charging emulator with programmable profiles
  • Charging connector inlet
  • Energy meter
  • Protection breakers
  • Display and control PC
  • Data logging for every parameter

Software

  • Charging emulator control and logging software

Models and specifications are listed in your proposal.

Curriculum

How students move through it.

Learners start on the LMS and the AI simulator, then run the experiments on the bench.

Indicative curriculum. The final module list is confirmed in your lab proposal.

Prerequisites

  • No prior charging-system experience is needed
  • Basic electrical knowledge helps
  • Complete the safety module first

How the LMS and simulator prepare learners

  1. Safety and orientationEmulator safety and lab rules.
  2. Charging fundamentalsVoltage rise, current taper and SOC.
  3. Charging methodsCC, CV and CC-CV profiles.
  4. Custom profilesDesign and run your own curve.
  5. Connector standardsType 2 and Bharat AC-001.
  6. Efficiency measurementCharge, coulombic and power loss.
  7. Fault testingProtection and plug-out scenarios.
Outcomes

What learners can do afterwards.

Explain how a charge cycle behaves
Program and run charging profiles
Measure charging efficiency and losses
Test how a system responds to charging faults
Who it helps

For institutions and for industry.

For institutions

Colleges and training institutes

  • Teach charging without high-voltage hazards
  • One emulator replaces many charger setups
  • Complete data logging for reports
For industry

Startups, SMEs and OEM teams

  • Test charging behaviour before hardware is ready
  • Check charger and battery compatibility
  • Review fault responses with logged data
  • Train charging and service staff
Enquire

Ask about the charging emulator zone.

Tell us about your institution or project. We reply with the zone details, equipment list and a proposal.

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