Considerations for Selecting an Electronic Load

When it comes to testing and development in electronics, selecting the right tools is vital. One of the most important tools you can have in your arsenal is an electronic load. Whether you’re working on power supplies, batteries, resistors, or other electronic components, electronic loads allow you to simulate real-world operating conditions.

However, it’s important that you choose the right type of DC or AC power source for your testing requirements. Below, we explore key considerations when selecting an electronic load so that you can make an informed decision that meets your needs.

Understanding Electronic Loads

An electronic load is a device that simulates electrical loads for testing power sources. These devices are essential for testing batteries, evaluating solar panels, and analyzing the capabilities of fuel cells. By drawing a controlled current, voltage, or power from the source under test, electronic loads help you check the power source’s performance, stability, and efficiency.

There are many different types of tests you can perform with an electronic load. A few examples include:

• Slew rate
• Discharge test
• Battery charge rate and efficiency

You can also stress test your designs to ensure they won’t short-circuit under normal fluctuation ranges. However, it’s vital that you choose the right type of electronic load for your testing requirements.

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Types of Electronic Loads

Understanding the different types of electronic loads can assist you in choosing the right one for your situation. The most common types of DC electronic loads include:

Constant Current Electronic Load

A constant current electronic load draws a steady amount of current from the power source. While the voltage will fluctuate, the current doesn’t change. You can use this device to keep the current consistent, making it an excellent choice for battery and power supply testing.

If most of your work revolves around battery and power supply applications, consider a benchtop or stationary electronic load with constant current capabilities. High-power DC electronic loads typically include constant current functionality and other settings that make them versatile enough to support a wide range of tests.

Constant Voltage Electronic Load

A constant voltage electronic load maintains fixed voltage levels. It’s the opposite of a constant current device, as the voltage remains steady and the current can fluctuate.

You can use constant voltage loads to ensure that voltage regulators maintain a stable output under varying conditions. You can also test high-performance power supplies to check whether they’re able to sustain a constant voltage output as the current demand changes.

Constant Resistance Electronic Load

Constant resistance electronic loads simulate a fixed resistance. The current drawn will be proportional to the applied voltage. A resistor simulator or emulator may require constant resistance electronic loads. You can conduct tests without the need for physical resistors, potentially reducing your prototyping and development costs.

Circuit testing applications also require constant resistance. You can evaluate your designs to see how they perform under specific resistance thresholds.

Constant Power Electronic Load

A constant power electronic load maintains a fixed power level. The machine adjusts the voltage and current to keep power constant, making this one of the most dynamic loads available. These devices are useful for testing battery discharge and enabling power supplies to deliver a consistent output. You can also gain insights into the performance and endurance of batteries and fuel cells.

Each type of electronic load has unique advantages and ideal use cases. Alternatively, you can invest in more sophisticated test equipment that includes several of these functionalities. Series programmable DC electronic loads allow you to run a wide range of evaluations, including discharge tests, waveform analyses, and much more.

Key Considerations for Selecting an Electronic Load

The accuracy and reliability of your tests depend on your equipment’s quality. You need to make sure your electronic load includes the right features and capabilities before making such a large investment. There are numerous functionalities to consider, including the following:

Load Capacity and Range

The load must have sufficient capacity to handle the maximum expected current, voltage, and power without exceeding its limits. Don’t purchase a load with just enough capacity to meet your expected test demands.

Instead, invest in a machine with a surplus of capacity so that you have the freedom to explore other analytics processes and push the limits of your designs. Thorough testing sets the stage for improved consumer satisfaction and better product performance.

The load must also have the range necessary to support a variety of testing conditions. Consider a multi-channel option so you can configure the unit for multiple assessments and speed up your entire testing process.

If you’ve got questions about the load capacity and range of a particular machine, contact the manufacturer for personalized support. The Elektro Automatik team is happy to help you identify the right piece of equipment for your situation.

Programmability and Control

If you plan on using novel techniques to test your designs, you’ll need a dynamic solution with multiple operating modes and settings. Programmable electronic loads enable you to set specific parameters and automate tests. Key features to look for in programmable models include:

• User-friendly interface
• Advanced control options
• Customizable test sequences

You want a machine that’s easy for your team to use and operate. It shouldn’t have a steep learning curve or difficult-to-read power meters.

Digital interfaces tend to be the most user-friendly, as they provide clear readings and accurate information at a glance. Your team will know precisely what settings they have selected and can ensure that test parameters align with project needs.

Figure 1: An EA series 10000 electronic load touchscreen

Even if you are not manually controlling your load, you should consider the convenience of having a front panel display and controls for test system development and troubleshooting. A full-color touchscreen display on EA electronic loads facilitates development and troubleshooting work.

Accuracy and Precision

Evaluate the electronic load’s specifications for accuracy and precision, checking that it operates within acceptable thresholds. High-precision models are essential for critical applications where even small deviations can impact outcomes. Resistors, circuits, and chips are a few examples of high-precision items that require extremely accurate testing protocols.

An autoranging DC power supply offers unparalleled accuracy and precision. It can automatically adjust certain input and output settings to keep specified variables within target ranges.

Cooling and Thermal Management

An electronic load can generate a tremendous amount of heat, especially if you are running a stress test or exposing your device to a prolonged current or voltage. The best testing devices have robust cooling and thermal management systems that are designed to prevent overheating and protect your equipment.

You’ll find two main types of systems: air-cooled and liquid-cooled. Air-cooled systems are generally simpler and cheaper. Liquid-cooled options offer superior cooling efficiency for high-power applications.

Consider the scope of your testing program to determine whether a liquid-cooled machine is a worthwhile investment. If you have more modest test parameters, an air-cooled option may work just fine. It’s all about finding the ideal fit for your project and team.

Safety Features

All forms of electronic testing can be dangerous. Make sure you invest in an electronic load with modern safety features, including the following:

• Overcurrent protection
• Overvoltage protection
• Thermal shutdown

These features protect both the electronic load and the device under test, ensuring safe operation. They will also reduce the risk of injury to your team.

However, a safe electronic load is only one part of preventing workplace accidents or equipment damage. You must also provide your team with adequate training on all equipment and make sure they strictly adhere to safety best practices.

Cost and Budget Considerations

High-end electronic loads offer advanced capabilities but require a larger upfront investment. Conversely, a simpler or budget-friendly device may cost far less, but it will also include fewer features and capabilities. You need to find a balance that considers both price and your performance requirements.

Make a list of essential capabilities, and then identify any features you’d like to have. Explore available electronic load options and find the solution that offers the best mix of value and functionality. Make sure it meets your project needs while landing within your budget and offering as many features from your wish list as possible.

Applications and Use Cases

Electronic loads are used in a wide range of industries for many unique applications. Here are some real-world examples:

• Battery Testing: Evaluating battery performance and capacity
• Power Supply Testing: Ensuring stability and efficiency
• Solar Panel Testing: Simulating load conditions
• Fuel Cell Testing: Assessing performance

If you plan on engaging in very niche testing protocols, a specialized load may be a good fit. However, if you conduct a wide array of assessments and experiments, you’ll need a more versatile option.

A programmable DC electronic load is one of the most popular configurations. You can use it for fuel cell testing, battery discharge evaluation, and more. After you’ve programmed specific testing protocols, future rerunnings of those evaluations become quicker and more efficient.

For more use cases and insights, check out our solar cell testing with DC power supply guide.

Frequently Asked Questions

What Is an Electronic Load, and How Does It Work?

An electronic load simulates electrical loads for the testing of power sources like power supplies, batteries, and solar panels. It works by drawing a controlled amount of current, voltage, or power from the source under test, allowing you to evaluate its stability and performance.

The electronic load can be programmed to maintain constant current, voltage, resistance, or power, depending on your requirements. This capability makes it extremely valuable for assessing how power sources respond under varying operating conditions.

You can adjust the settings to meet the unique specifications of your test. In so doing, you’re able to ensure that your designs perform up to expectations in real-world applications.

What Are the Benefits of Using a Programmable Electronic Load?

A programmable solution provides added flexibility and precision. You can set specific parameters and automate complex test sequences, improving efficiency and consistency. Programmable loads are ideal if you need to run repetitive and precise testing scenarios, such as battery life cycles and power supply validation.

Programmable loads support multiple modes, including constant current, voltage, resistance, and power. They are versatile enough to meet a wide range of testing needs. Top options also feature advanced monitoring and data logging capabilities, making it easy for your team to analyze test results.

How Do I Determine the Right Electronic Load for My Application?

Start by identifying the key specifications required for your tests. Are you manipulating the current, voltage, or power? Consider the type of load that best suits your testing requirements based on expected criteria.

Evaluate the unit’s accuracy and precision to ensure reliable results. Look for features like programmability and a user-friendly interface to minimize your team’s learning curve.

And don’t forget to consider the unit’s cooling and thermal management capabilities. If you are going to run prolonged evaluations or repeated tests in rapid succession, you’ll need a more robust cooling unit to prevent overheating.

What Safety Features Should I Look for in an Electronic Load?

Look for features that protect the load, your device, and your team. Overcurrent protection prevents excessive current from damaging your equipment’s circuitry. Similarly, overvoltage protection safeguards against voltage spikes that could harm the load, the power source, or your team.

Thermal shutdown represents another must-have safety feature. It turns the device down if it overheats. Make sure your unit offers reverse polarity protection as well, as it prevents accidental damage if your team connects the system incorrectly.

Are There Different Types of Cooling Systems for Electronic Loads?

Electronic loads use different types of cooling systems to manage the heat generated during operation. The most common cooling methods are air and liquid cooling.

Air-cooled machines use fans to dissipate heat and are generally more cost-effective and easier to maintain. They are suitable for low to moderate-power applications. Liquid-cooled electronic loads use a liquid coolant to transfer heat away from the device. This method dissipates heat more effectively, but the machines come at a higher price point and require more in-depth maintenance.

Explore EA’s Range of Electronic Loads

Elektro Automatik (EA) offers a wide selection of high-power AC/DC power sources. Our autoranging testers can thoroughly evaluate the capabilities of your equipment and prototypes. We also offer bidirectional DC power supply test solutions.

Schedule an online demo to explore the capabilities of our electronic loads. Once you’ve identified the programmable electronic load that best aligns with your intended use case, request a quote from our team.