EV Charging Infrastructure Manufacturing worked example

Burn-In Test Load with average burn-in electrical load of 600 kW: a worked example

Push average burn-in electrical load up to 600 kW and the picture changes. This example computes every intermediate figure at that operating point. a test manager needs energy cost and load impact for charger burn-in

The inputs for this scenario

  • Average burn-in electrical load: 600 kW (raised for this scenario; the documented default is 240)
  • Burn-in test duration: 8 hr (unchanged)
  • Blended electricity rate: 0.13 $ / kWh (unchanged)
  • Chargers or power modules tested: 12 units (unchanged)

Working through the calculation

  • Applying the documented formula (Burn-in energy cost = average burn-in load × burn-in duration × blended electricity rate) to the inputs above produces each figure below.
  • At this operating point the engine returns 624 $ for burn-in test energy cost, the number this scenario is built around.
  • At this operating point the engine returns 4,800 kWh for burn-in test energy used.
  • At this operating point the engine returns 52 $ / unit for burn-in energy cost per unit.
  • At this operating point the engine returns 78 $ / hr for hourly burn-in energy cost.

How this compares with the baseline

  • Against the tool's baseline example, where average burn-in electrical load sits at 240 kW and the headline result is 250 $, this scenario comes in 150% above the baseline at 624 $.
  • It computes the total electricity cost and kWh of a burn-in run at a given average load, duration, and rate, then divides by the units tested for a per-unit cost. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Burn-in test energy cost: 624 $ (headline result)
  • Burn-in test energy used: 4,800 kWh
  • Burn-in energy cost per unit: 52 $ / unit
  • Hourly burn-in energy cost: 78 $ / hr

Run it with your numbers

  • Every input above is editable in the live Burn-In Test Load calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.