Automated Test Equipment
PCBA End of Line (EOL) testers validate the PCBA hardware and software functionality of Electronic Control Units (ECU) using In Circuit fixtures.
- Access the PCBA signals through test pads and solder pads
- Simulation and measurement of Digital, Analog and PWM Signals
- Automatic validation of ECU (DUT) outputs
- Communication interfaces validation like CAN, CAN-FD, LIN, RS422, etc.,
- Simulation of high-speed signals like Engine speed, SENT, etc.,
- Bootloader and Software flashing test
- Boundary conditions testing like over current, short circuit, fault simulations, etc.,
- Signals are accessed through highly durable spring-loaded pins
- LabVIEW, TestStand based Graphical User Interface (GUI) and functional software
- Different types of ECUs can be tested using a single test system
- Multiple DUTs can be tested simultaneously to increase productivity (JPH)
- Traceability of DUTs, Report generation facility, Label printing facility FPY analysis options, etc., are provided for productivity analysis
- Faster and error free testing
- Industry 4.0 compliant systems (MES server update, component traceability, cloud update, etc.,)
ECU Functional Tester is a wider category with specific variants as mentioned below
- BMS Test System
- VCU Test System
- MCU Test System
- DC-DC converter Test System
- IC Engine ECU Test System
Given below are the Features of ECU functional test
- ECU functional tester performs testing of the ECU after enclosure assembly (Black Box testing of the ECU)
- Signals are accessed through highly durable spring loaded pins and ECU connectors
- Complete plant model simulation to the ECU
- Simulation and measurement of Digital, Analog, and PWM Signals
- Automatic validation of ECU (DUT) outputs
- Communication interfaces validation like CAN, CAN-FD, LIN,RS422, etc.,
- Simulation of high-speed signals like Engine speed, SENT, etc.,
- Simulation of Battery cell voltage,temperature,etc.,
- Boundary conditions testing like over current, short circuit, fault simulations, etc.,
- Software flashing and updating through Bootloader
- LabVIEW, TestStand based Graphical User Interface (GUI) and functional software
- Different types of ECUs can be tested using a single test system
- Multiple DUTs can be tested simultaneously to increase productivity (JPH)
- Historical data store of test results
- Traceability of DUTs, report generation facility, label printing facility, FPY analysis options, etc., are provided for productivity analysis
- Faster and error free testing
- Industry 4.0 compliant systems (MES server update, component traceability, cloud update, etc.,)
Thermal camera method: This tester monitors the temperature of the ECU / components like MOSFETs / battery cells using thermal vision cameras and sensors.
Elevated ambient temperature method: This tester evaluates ECU thermal performance by driving ECUs at peak loads in elevated temperature conditions using thermal chambers.
- Accelerated and full Load testing of ECUs
- Precision thermal vision cameras and thermal chambers are used
- NI Vision, LabVIEW, TestStand based Graphical User Interface (GUI) and functional software
- Multiple DUTs can be tested simultaneously to increase productivity (JPH)
- Historical data store of test results
- Traceability of DUTs, report generation facility, label printing facility, FPY analysis options, etc., are provided for productivity analysis
- Faster and error free testing
- Industry 4.0 compliant systems (MES server update, component traceability, cloud update, etc,)
In Circuit Tester checks the PCB Assembly (PCBA) components by measuring components' active and passive parameters using customized fixtures.
- Bed of Nail method is used for testing
- Access the PCBA signals through test pads and solder pads
- Signals are accessed through highly durable spring loaded pins
- Short circuit and continuity testing of PCB traces
- Cost effective fixtures (manual and pneumatic)
- Historical data store of test results
- Traceability of DUTs, report generation facility, label printing facility,
- FPY analysis options, etc., are provided for productivity analysis
- Faster and error free testing
- Fully Automated and Closed loop MCU test system with command and Response through CAN.
- Simulates low voltage Digital signals like High side and low-side switch inputs
- Simulates low voltage Analog signals like throttle, etc.,
- Simulates passive temperature sensor signals
- Simulates quadrature PWM signals like encoder etc.,
- Measures and validates MCU outputs like sensor supply
- Validates CAN communication from MCU with various signal input scenario
- Simulates Motor Load using 3Phase R-L Load
- Measures MCU 3Phase Power output and efficiency
- Software flashing and updating features
- Pneumatic fixture and Spring loaded pins for easily engaging and disengaging MCU
- Industry 4.0 system with MES server communication
- Report generation and traceability for individual DUT
The Test system validates the thermal and electrical performance of EV Battery Pack while charging and discharging. This system can handle power up to 60KW.
- Thermal runaway detection
- Cell level voltage and temperature validation
- BMS calibration
- Battery module assembly validation
- Battery wiring connection correctness validation
- Historical data store of test results
- Traceability of DUTs, report generation facility, label printing facility, FPY analysis options, etc., are provided for productivity analysis
- Faster and error free testing
- Capable of handling high currents up to 1000 Amps
- CAN ready system for communicating with BMS
- Charge-Discharge Cycler helps the manufacturer to meet AIS156 standards for EV battery packs
- Simulates battery cells to test BMS ECUs
- Simulates battery cells' temperature sensors
- Tests Cell balancing feature of BMS ECUs
- Battery cells and pack fault simulation
Variants
- Manually controlled
- PC controlled
- Open loop
- Close loop
Features
- Power Input – 230V,5A
- No. of Cells – Standard 24 ( customizable as per requirement)
- Max Current o/p per cell – 100mA
- Voltage O/P per cell – 0 to 5V variable as per knob setting
- Temperature simulation – 24 cells (customizable as per requirement)
- DC, single phase, and 3 phase AC load bank
- Programmable R-L-C load bank for AC source
- Programmable resistive load bank for AC/DC source
- Constant Current and Constant Power functionality
- PC controlled load bank with user friendly HMI
- Load banks can be paralleled or connected in series to increase the load capacity
