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Test Equipment for Sub-Assemblies of Electric Vehicles

14 April 2011 - IPTE Factory Automation (FA) announces a test system for the battery charger block (BCB), a sub-assembly needed for the management of the charging procedure and the functional control of the storage-battery pack in electric vehicles (EV). The test system was developed in cooperation with a customer.

The electrical specifications of the BCB sub-assemblies are quite impressive: they have to successfully master high-power situations of up to 4000 watts and AC/DC voltages between 12 and 410 volts without any complications. Additionally, high data rates are exchanged with the po-wered vehicle over the signal lines, and in order to control all these parameters and functions they need to be comprehensively verified and documented for the purposes of traceability by the test system.

IPTE FA’s custom-specific solution incorporates a whole range of different tests which have to be provided with high speed and repeatability. Therefore, the following critical parameters and functions are subject to scrutiny: electrical isolation, contact continuity, connector conditions, self-diagnostics, data communication, stream of charge characteristics and the correlating current consumption, as well as the overall specifications and their compliance in regard to the entire assembly. The application was developed in cooperation with IPTE’s client Lear.

During the test of the electrical isolation, for example, no current leakage is allowed when high voltage is applied. And it is also clear that when operating with high cur-rents, no voltage-drop can be tolerated, as is also the case with the continuity test. It almost goes without saying: all electrical connections have to be perfect and verified by reliable connector tests. The test of the self-diagnostic feature examines the input and output signals in regard to the function specified. The test of the unit communication is done in a similar way whereby the data exchange with the peripherals is carefully monitored. Of crucial importance for ensuring a very long life for the battery pack is an optimum charging curve complying with the specified and desired characteristics: these are very carefully and extensively checked together with the entire multitude of different input currents in the different operation modes. And eventually the BCB tester checks for the compliance of the assembly regarding all the relevant standards and safety regulations valid for those EV functional units.

www.ipte.com


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