Audi has opened a new electric-charging test center in Ingolstadt, where electric Audi models are tested under various global charging conditions, including 110 or 230 volts and 50 or 60 hertz, similar to those in regions like China and the United States. This allows Audi to incorporate real-world testing results into vehicle research and development, ensuring customers worldwide receive the best charging experience. Audi is one of the first automakers to use a flexible grid simulator, which began operation earlier this year. The simulator, located at the center, can replicate the voltage and grid configurations from non-EU countries, using charging stations from multiple manufacturers. Developed by Bosch Rexroth in partnership with Schmidbaur, the installation enables Audi to conduct testing based on real-world conditions in various global markets.
Global power grids vary in configuration, voltage, and frequency, even though electricity is accessible from sockets worldwide. For instance, devices designed for 120 volts and 60 hertz, common in North America, can’t operate on the 230 volts and 50 hertz standard in Europe. “With the grid simulator, we can test if our models can charge successfully at stations in the US or China, for example,” says project manager Daniel Ettinger.
The flexible 500 kW simulator was developed by Bosch Rexroth in collaboration with Audi – specifically for Audi. The new system can deliver voltages between 100 and 540 volts and frequencies between 40 and 65 hertz. It supports single-phase, two-phase, and three-phase networks, as well as split-phase operation.
On their own factory premises, Audi engineers are using the electric-charging test center with its grid simulator to gain important insights into how electric cars and charging stations interact. They then apply their newly acquired knowledge to adapt vehicle software even better to the charging stations commonly used worldwide and to further improve the charging performance of the Audi models. The endeavor saves time and money, as it reduces the need for extensive testing abroad. At the same time, customers benefit from a charging experience that is individually designed for local conditions – so that charging is even faster and easier in all four corners of the globe.
