Capability / real EV and EVSE interoperability testing

Test a communication change during a real charging session

Change communication towards the real EV or EVSE while both partners stay connected. Use PLC manipulation for CCS/NACS, the CAN Manipulating Gateway for DC-China (GB/T DC), or Control Pilot variation for AC low-level charging.

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A live gateway changes selected supported communication between a real EV and a real EVSE for controlled interoperability debugging

Real EV + EVSEBoth partners stay connected

One controlled changePLC, GB/T DC CAN or AC Control Pilot

Before and afterThe synchronised response, compared

Clear resultThe hypothesis, evaluated with the measurements

The communication change

Change the communication condition. Observe the real response.

A passive gateway records the original charging session. Manipulating Gateway introduces a controlled communication change and shows the response to a defined deviation.

CCS/NACS: PLC message manipulation

For CCS/NACS, manipulate DIN 70121 (DC) and ISO 15118 (AC and DC) messages in either direction, towards the EV or EVSE. With DIN 70121 and ISO 15118-2, set PLC message parameters to valid or invalid test values representable by the XML schemas, including mixtures of both standards.

AC low-level: test the EVSE

The real EV serves as an AC load. Varying the Control Pilot voltage, for example through resistances, shows the charging station’s response at signal boundaries.

AC low-level: test the EV

The real EVSE serves as the AC power source. Varying the Control Pilot duty cycle shows how the vehicle adjusts its charging current and charging behaviour.

CAN communication

DC-China (GB/T DC): bidirectional CAN manipulation

Pass, filter or manipulate CAN messages towards the EV or EVSE. Edit individual values and hexadecimal data within messages, modify J1939 CAN frame/header fields including ID, Data Page, Priority and Reserved Bit, and add delays per message type.

From recording to comparison

Record the session, apply the change and compare results

Record the baseline
Record the original charging session and identify the suspected deviation.
Define one change
Select a supported PLC parameter, GB/T DC CAN message value, frame field or delay, or a CP voltage or duty-cycle variation. Define the response you expect.
Apply it live
Activate the configured change while the real EV and EVSE remain connected.
Compare the response
Compare communication, pilot signals, voltage and current before and after the change. Save the settings and both recordings for review.

The real charging pair, investigated

Test charging behaviour with the real EV and EVSE

Mismatch

Parameter and signal boundaries

Shows how a specific PLC parameter or AC Control Pilot change affects the observed charging behaviour.

Integration

Optional behaviour

A controlled communication change tests an implementation assumption directly.

Coordination

Supplier alignment

The charging session before and after the controlled change is compared. Give both teams the same recordings to review their interpretation together.

Illustrative AC low-level example · EV under test

Does a change in the CP duty cycle alter the charging behaviour?

Before

During AC charging without PLC, the vehicle repeatedly changes its current demand or stops charging. Record the CP duty cycle and measured current.

Controlled change

Apply a defined CP duty cycle with Manipulating Gateway while the real EVSE supplies AC power to the vehicle under test.

After

Check whether the current response and charging continuity change. The comparison helps test the suspected cause; it is not a measured customer result.

Test setup

Plan a controlled change for your real charging pair

EV, EVSE, charging standard and edition, physical interface and security context are defined. Observed failure, communication element to change, expected recovery, measurement layers and needed records are described.

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Frequently asked questions

Manipulating Gateway FAQ

Does the gateway replace either charging partner?

No. A real EV and real EVSE stay connected. Manipulating Gateway changes selected supported communication between them.

How is it different from Professional Simulation?

Manipulating Gateway keeps both real charging partners connected and changes their communication. Professional Simulation controls a simulated EV or EVSE. Alongside the CCS PLC functions, DC-China (GB/T DC) and CHAdeMO Professional Sim support advanced parameters, communication-error simulation and state-machine robustness tests. Their CAN loss frequency and cycle times can be configured per message type.

What can I change with Manipulating Gateway?

For CCS/NACS, change PLC message parameters for DIN 70121 (DC) and ISO 15118 (AC and DC); DIN 70121 and ISO 15118-2 values may span the ranges representable by their XML schemas. The DC-China (GB/T DC) Manipulating Gateway passes, filters or manipulates CAN messages in both directions. Change individual values and hexadecimal data, edit J1939 frame/header fields such as ID, Data Page, Priority and Reserved Bit, and add delays per message type. For AC low-level charging without PLC, vary CP voltage or duty cycle.

What records should be retained?

Keep the original interaction, exact change settings and synchronised recording of the resulting session together with DUT versions and the technical conclusion.

What is needed to scope a project?

Describe both charging partners, protocol and edition, connector and security context. Include the observed failure, selected change, expected recovery, measurement scope and release requirements.

Controlled real-pair change

Define the communication change for your test

Real EV and EVSE, observed failure, supported communication element and expected response are described.

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