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Better Precision
Electronic loads offer a higher degree of accuracy and precision than traditional load banks due to their advanced measurement and control circuits, which minimize errors and ensure stable operation.
Improved Flexibility
Electronic loads are easy to program and feature intuitive user interfaces that provide a wide range of control options, including real-time voltage and current adjustment, current ramping, and continuous waveform simulation.
Reduced Size and Weight
Electronic loads can be designed to be significantly smaller and lighter than traditional load banks, making them more portable and easier to move between testing sites.
Enhanced Features and Capabilities
Electronic loads often provide a range of advanced features, such as adjustable output impedance, dynamic loading, and automated testing, which make them more versatile and efficient for a variety of testing needs.
Lower Energy Consumption
Electronic loads tend to consume less energy than traditional load banks, making them more environmentally friendly and cost-effective to operate over the long term.
Safer Operation
Electronic loads feature advanced monitoring and protection circuits that can prevent damage to equipment under test, resulting in safer and more reliable testing procedures.
The purpose of an electronic load is to simulate a wide range of load conditions, such as current, voltage, power, and resistance, that an electronic device may encounter during its normal operation. This allows manufacturers and designers to test the performance and reliability of their products under a variety of realistic scenarios, which helps improve the quality and efficiency of the devices they produce. Electronic loads are commonly used in industries such as automotive, aerospace, telecommunications, and manufacturing, where precise and reliable testing of electronic components and systems is critical.
How Electronic Loads Work
Electronic loads are devices that simulate the behavior of a physical load, allowing testing, measurements, and analysis of electronic circuits without the need for an actual load. Electronic loads are useful tools for testing power supplies, batteries, and circuits.
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Electronic loads work by converting electrical energy into heat, just like real loads. The load is connected in parallel with the device under test, and its resistance can be adjusted to provide the desired load impedance. The load control circuitry adjusts the load resistance to maintain the current or voltage level that is specified by the user.
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In constant current mode, the load will draw a constant current from the power source, regardless of the voltage level. In constant voltage mode, the load will consume a constant amount of power, and the load resistance is adjusted accordingly based on the changing voltage level.
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Electronic loads often feature advanced functionality, such as overvoltage protection, overcurrent protection, and various modes of operation, including constant power, constant current, and constant resistance.
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Electronic loads are commonly used in the electronics industry, such as for testing power supplies, solar panels, and batteries, as well as in research and development of electronic circuits.
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Battery testing
Electronic loads are commonly utilized to test the capacity and efficiency of batteries. They can simulate real-world loads and provide accurate results, making them useful in battery manufacturing and testing.
Power supply testing
Electronic loads help in testing power supplies by simulating a load on them. This helps to ensure that the power supply can handle the maximum load and provides constant voltage and current output.
Solar panel testing
Electronic loads are used to test the efficiency and output of solar panels. They help simulate various light and temperature conditions to ensure the system can perform well under different scenarios.
Motor and generator testing
Electronic loads can be used to test the output and load capacity of motors and generators in various applications.
LED driver testing
Electronic loads help in testing the performance of LED drivers. They can simulate different loads, voltage, and current conditions to ensure the LED driver can perform well under different scenarios.
DC-DC converter testing
Electronic loads can be used to test DC-DC converters. They simulate different loads and conditions to ensure the converter can perform well under various scenarios.
Automotive testing
Electronic loads help simulate various electrical loads in automotive applications, such as alternators, electric motors, and batteries. This helps in testing the performance and durability of various automotive components.
The load module is the main component of an electronic load. It is responsible for creating a load on a power source. It is usually made of power mosfets or power transistors that can handle high current and voltage.
The cooling system is essential to maintain the temperature of the electronic load. It can be a fan, heatsinks, or a combination of both. The cooling system helps to dissipate the heat generated during the testing process.
The control circuit is responsible for controlling the load. It is usually made up of microprocessors or digital signal processors that enable the electronic load to be adjusted to various input signals.
The user interface is a display panel that is used to display the measured data, testing parameters, and other relevant information. It enables the user to control and monitor the operation of the electronic load.
The protection circuit is designed to protect the electronic load against overvoltage, overcurrent, and short circuits. It is crucial to protect the electronic load and the device under test from any damage.
Input filters can be used to eliminate any unwanted signals that may affect the accuracy of the electronic load. It can also prevent any electrical noise generated by the device under test from flowing back to the electronic load.
The power management system controls the power supply to the electronic load. It regulates the voltage and current supplied to the load module, protecting it from voltage and current spikes.
Resistive Loads
These are the simplest electronic loads, consisting of a resistor that is used to dissipate electrical power in the form of heat.
Capacitive Loads
These loads are used to simulate and test the behavior of capacitors under different electrical conditions.
Inductive Loads
These loads are used to test the behavior of inductors under different electrical conditions.
LED Loads
These electronic loads are designed to test the power and electrical characteristics of LEDs.
DC Power Supplies
These electronic loads act as power supplies and can be used to simulate the behavior of different electrical devices under various conditions.
Variable Electronic Loads
These loads can be adjusted to simulate different power and voltage settings, making them ideal for testing a variety of different electrical devices.
Automotive Electronic Loads
These loads are specifically designed for testing automotive electrical systems, including batteries, alternators, and starters.
Digital Electronic Loads
These advanced loads use digital circuitry to provide precise control over voltage and current, making them ideal for testing complex electronic circuits.
Tips for the correct use of electronic loads
Read the manual: Before using an electronic load, read the manual thoroughly to understand the functions, limits, and safety precautions.
Set the voltage and current limits: Before connecting the DUT to the electronic load, set the voltage and current limits within the range that the DUT can safely handle.
Connect the DUT correctly: Ensure that the DUT is connected correctly to the electronic load. Use appropriate cables and connectors to avoid voltage drops, noise, or short circuits.
Adjust the load settings carefully: Adjust the load settings gradually and monitor the DUT's response to avoid sudden current spikes or voltage surges.
Monitor the temperature and overheating: Electronic loads generate heat during operation, which can damage the load or DUT if not monitored. Use a temperature sensor or thermal imaging camera to monitor the temperature and prevent overheating.
Use overload protection: Most electronic loads have overload protection features that can prevent damage to the DUT when the load exceeds the set limits. Use these features when testing high-power devices to prevent unexpected failures.
Conduct tests in a safe environment: Electronic loads can generate high voltages and currents, so conduct tests in a safe environment and follow all the safety precautions in the manual.
Tip 1. Testing a battery – constant current (cc) mode
The current priority mode is the most popular of testing modes for an electronic load. A basic use for this setting would be to measure the total energy stored in a battery. As the battery supplies current, its voltage drops. By using this characteristic (voltage profile), we can predict a battery’s capacity in terms of time.
As a constant current test example, we use a Li-ion 18650 battery. The capacity (C) measured in mAh, is used to calculate the current for charging and discharging. When charging, the current is limited to 0.5C (in our example 1250mA) charging needs to stop before the battery voltage reaches 4.2V.
Discharging uses a similar constant current process. A sizeable current drain is inadvisable as this shortens the life of the battery. Also, it’s crucial to stop pulling power at the point where the battery reaches its low voltage limit (2.5V) to prevent further potential damage.
A battery can support discharge at their max rate. However, Li-ion batteries yield a higher capacity if discharged at a fraction of this value. Low temperatures can influence both voltage and capacity.
Many other battery attributes are determined using DC Electronic loads, capacity, internal impedance, charge /discharge long term performance, low-temperature behavior, and abusive extremes. Capacity being the most common, as it yields the battery’s run time. Tests using variable current drain to simulate a device as it comes out of sleep mode into an active state, for instance, can paint a picture of how the battery holds up to various discharge rates.
Li-ion batteries will have a long life when they operate over a narrow range. Avoiding a high charge voltage (>4.1V) and a low discharge voltage (<2.6V) reduces the stress on the battery. Calculating the battery capacity multiplies the discharge current 500 mA by the run time, 4.5h, or 2250mAh. The measured capacity is slightly lower than specified due to the narrow operating range 2.6 to 4.1V
The majority of power supplies use a voltage regulation circuit to provide a constant voltage. In certain conditions, however, the load may exceed the circuit’s ability to maintain a constant voltage, and as a result, transient voltage spikes can manifest.
To quantify the transient response, set the load so that the power supply is supplying full output voltage with a current that is half the supplies maximum. Then suddenly increase the load to force the power supply to provide maximum current, and then decrease the load to restore the power supply to half capacity.
The time taken for a power supply to recover from a significant change in load is known as its transient response time.
The supply is considered recovered, once stabilized within its settling band. As an example, the Keysight E36312A specifies less than 50us to recover within the 15mV settling band. This follows a load change of 50% to 100% of the maximum output current.
Measuring this response time using load resistors and switches could pose a challenge. Power resistors, often wound components, possess an inductance, which can interact with the transient from the power supply. The use of DC electronic loads avoids this additional interaction.
The DC electronic load can be configured in either resistance or constant current mode to achieve these measurements. In the former, the value of resistance required to generate the desired current (50% or 100%) would need calculation. The latter simply requires the load to be set to the desired current values.
With the load configured, the next step would be to create a waveform (step or pulse) to load the power supply in such a way to generate the transient(s). The Keysight N6700 series have a series of built-in waveforms that facilitate this. Generating a dynamic load is created by describing just a few points. A step waveform generates a single transient as the current value changes from 50% to 100%, a pulse generates two transients, one for each edge.
In the event of a fault condition, power supplies include a current limiting protection circuit. To protect the supply itself and connected equipment. When using an original equipment manufacturer (OEM) Power Supply. It’s important to know that the performance in this regard is right for the intended application.
There are generally 3 types of current limits
1. Conventional current limiting
2. Power supplies that can transition between constant voltage (CV) to constant current (CC)
3. Fold-back current limiting power supplies
The first two are very similar in function, differing only in the degree of regulation in the constant current region this region is adjustable in the case of the supply CV/CC capability.
Current limiting capability test
The test begins with the DC electronic load configured to draw a minimal current from the power supply. The loadresistance is reduced in steps while monitoring the output voltage and current. The output voltage remains constant as the current increases until reaching the current limit, then the voltage drops.
This drop is known as the crossover region. As the load resistance decreases further, the current limiting circuitry of the power supply is now active. There is a sharp transition to this constant current region with a high-quality supply.
DC-DC converters, within their working range, can accept a wide range of input voltages and provide an isolated stable output voltage. Their use in electronics is commonplace. Emergency vehicles can make use of a step-up DC-DC converter to power computers and their peripherals.
Many computers require a DC supply voltage in the range of 14-19V, using a DC-DC converter to power these devices directly from the vehicle’s 12V battery, is much more efficient than using a AC mains inverter to power each of the devices via its AC-DC power supply.
DC-DC converters are efficient, typically better than 96%, and are constant power (CP) devices. With a constant load, they consume constant power by increasing the input current as their supply voltage drops.
Protecting the converter
Because of its nature, the converter requires more than a single current limit. A converter needs more current at lower supply voltages and less current at higher voltages. A single limit set to handle the large current necessary at a low voltage will not protect the converter at a higher supply voltage. At a higher voltage, the converter would endure too much power before tripping the current protection. The key is to select a power supply with over power protection (OPP) or output LIST capability.
A second safeguard, overcurrent protection (OCP) can disable the output when an overcurrent condition persists. At the current limit, the supply holds the current constant (CC) but allows the output voltage to fall. Potentially, the voltage can drop below the operating voltage of the converter, letting it go into an unstable state. Overcurrent protection prevents this by shutting off the supplies output.
A third safeguard is an undervoltage inhibit set on the DC electronic load. In a test, the DC electronic load protects the converter by monitoring its’ output voltage and only draws current while it’s sourcing a nominal voltage. An inhibit function, turns the load off until the converter restores its proper output voltage.
Our Factory
Established in 2016, PH Tool and Test Equipment Inc strives to continually improve itself and offer the best value for its customers. We offer our customers several practical, efficient and cost effective solutions for their business or projects' test equipment needs. Whether you need to rent & buy test equipment, repair test equipment, sell or trade equipment, we are committed to providing superior customer service and high quality electronic test equipment.
Q: How do electronic loads work?
Q: What is the meaning of electronic load?
Q: What is the constant resistance mode of the electronic load?
Q: What are the three types of electrical load?
Q: What are the electronic load settings?
Q: What does a DC electronic load do?
Q: How do you control load regulation?
Q: How do you check load regulation?
Q: How to set DC electronic load?
Q: How do you balance electrical load in a house?
Q: How do you check circuit load?
Q: What are the different types of DC electronic loads?
Q: What is the difference between AC load and DC load?
Q: Is a heater a resistive or inductive load?
Q: What is controlling load?
Q: What determines the load regulator?
Q: Why do we need load regulation?
Q: What is the difference between power supply and load?
Q: What happens if load is unbalanced?
As one of the leading electronic loads manufacturers and suppliers in China, we warmly welcome you to buy high-grade electronic loads in stock here from our factory. All our products are with high quality and competitive price. For more information, contact us now.
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