The testing ground of the heart: Aging test of the on-board charger (OBC) in new energy vehicles

In the booming era of new energy vehicles, people's attention is focused on the range of travel, intelligent driving and the cool appearance of the cars, but they rarely pay attention to the "unknown heroes" hidden inside the vehicles. The on-board charger (OBC) - this "energy bridge" connecting the power grid and the car's battery pack - is quietly undertaking the crucial mission of converting alternating current into direct current. And ensuring the safety and stability of this bridge for decades is a "ultimate testing ground" composed of a series of precise and rigorous aging test cabinets.

The aging test cabinet emits a low-pitched operating sound, resembling the "time accelerator" of OBC. Here, the aging cabinet simulates the most extreme usage scenarios in the real world under strict standards. 

In the "temperature shock chamber", the OBC undergoes verification of its adaptability to extremely hot environments in a high-temperature cabinet; the "power grid pressure testing area" simulates drastic voltage fluctuations from 90V to 265V, and even deliberately creates instantaneous surges like lightning to test the resilience of the circuits. The most astonishing part is the "life acceleration aging bench", which compresses the ten-year usage wear and tear into a concentrated display within a few hundred hours by increasing the current load and extending the operating time. 

Each OBC must prove itself in this simulated "lifetime": Can its conversion efficiency remain above 95% continuously during operation? Will its insulation performance deteriorate as it "ages"? Can its cooling system handle the "thermal stress" caused by long periods of full-load operation? Only products that have passed these rigorous tests can obtain the passcode to enter the market.

One of the core missions of the aging test is safety verification. Every rigorous experiment conducted within the test chamber is a solemn commitment to the safety of consumers' lives and property. The short-circuit protection test verifies whether the power supply can be cut off within milliseconds in case of circuit abnormalities; the leakage current monitoring ensures that no dangerous voltage is generated even in a humid environment; the insulation withstand voltage test applies high-voltage electricity several times the working voltage to test the reliability of every insulation gap. 

The engineers from Zhongkong Yuan, a well-known manufacturer of aging test cabinets in the industry, often say: "What we test is not the product, but the risk boundary." It is precisely this zero-tolerance attitude towards risks that enables the OBCs that pass the complete aging test to ensure the charging safety of vehicles in complex conditions such as thunderstorms, humid environments, and unstable power grids, and prevent the occurrence of serious accidents like spontaneous combustion.