End-of-line test of the end device

After assembly, the electrical connections, communication functions and safety-related properties of the wallbox are validated in the final test. Barcode scan and comparison of unit data via the diagnostic interface Testing at different mains voltages and loads Functional and communication test with the charging connector installed Checking the pilot voltage under different simulated loads High-voltage test at 4.25 kV in accordance with VDE regulations Protective conductor test at 25 A

Control, signal and process testing

Controls and output signals are tested and production data is finally documented on the device. Device temperature test Testing the buzzer button Functional testing of the LED bars through interaction with the operator Writing production data to the unit under test

Flexible adaptation to variants

The test system can be quickly adapted to new wall-mounted charging stations using modular hardware and software components. Interchangeable workpiece fixtures Modular software architecture Rapid conversion for new model variants Economical production even for smaller quantities

No electric cars without charging stations – and no reliable charging infrastructure without precise test technology

The transformation of the automotive industry is disruptive: conventional components are giving way to electric motors, batteries and complex charging units. As a technology leader for complex, mechatronic and fully automated test systems, MCD Elektronik offers turnkey solutions tailored precisely to the requirements of electric mobility. From the initial risk analysis to on-site commissioning, this project was completed in just 16 weeks.

Challenges and concept

Wall-mounted charging stations for electric vehicles must operate reliably under different mains voltages and current loads. MCD Elektronik therefore developed a test system for a wallbox manufacturer that safely and automatically tests both the electronic circuit board before installation and the fully assembled end device.

31107_wallbox-EOLT_innen-clean-4412x2871

Blinker, Kamera, Heizung und Assistenzsysteme.

EOLT Systems

Außenspiegel

EV wall-mounted charging station

End-to-end testing from electronics to end device

During the functional test, the electronic circuit board is contacted via a bed of nails, programmed with the appropriate firmware and tested under stringent safety requirements. Different mains voltages, simulated load conditions, and residual-current, temperature and signal tests reproduce real operating conditions.

In the subsequent end-of-line test, the fully assembled wall-mounted charging station is tested. Electrical connections, communication, controls, LED bars and buzzers are validated automatically. Interchangeable workpiece fixtures and a modular software architecture enable rapid adaptation to new model variants.

Test stages

Functional test & EOL test

High-voltage test

4.25 kV

Protective conductor test

25 A

Ein flexibler End-of-Line-Prüfstand

MCD entwickelte hierfür einen flexiblen End-of-Line-Prüfstand, der sämtliche Varianten innerhalb von weniger als 30 Sekunden prüft. Das System kombiniert optische, mechanische und elektrische Prüfverfahren zu einem durchgängigen Prüfkonzept.

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Test and functional scope

The test system combines functional testing of the electronic circuit board with the final end-of-line test of the fully assembled device:

Test fixture for wallbox circuit boards

Detailed view of the test area

Contacting, wiring and test technology

EOL test stand for EV wall-mounted charging stations

Overall view of the test station

Test fixture, operator monitor and system technology

Before installation, the circuit board is identified, programmed and tested under defined electrical and thermal conditions.

Barcode scan for process interlocking and verification of testability
Comparison of unit data via the system’s data connection
Firmware programming
Testing at different mains voltages
Functional and load testing
Checking the pilot voltage under electronically simulated load
Residual-current and temperature test
Testing the buzzer signal using FFT spectrum analysis

After assembly, the electrical connections, communication functions and safety-related properties of the wallbox are validated in the final test.

Barcode scan and comparison of unit data via the diagnostic interface
Testing at different mains voltages and loads
Functional and communication test with the charging connector installed
Checking the pilot voltage under different simulated loads
High-voltage test at 4.25 kV in accordance with VDE regulations
Protective conductor test at 25 A

Controls and output signals are tested and production data is finally documented on the device.

Device temperature test
Testing the buzzer button
Functional testing of the LED bars through interaction with the operator
Writing production data to the unit under test

The test system can be quickly adapted to new wall-mounted charging stations using modular hardware and software components.

Interchangeable workpiece fixtures
Modular software architecture
Rapid conversion for new model variants
Economical production even for smaller quantities

Bauteilaufnahme im EOL-Prüfstand

Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

2018_Wallbox-seitlich-mit-Pruefer-3 (3)-2000x1947

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

Spiegeleinstellungen

Kamerasysteme kontrollieren Lichtfunktionen und Spiegelstellungen, während Antriebe, Klappmechanismen und elektrische Funktionen automatisiert getestet werden.

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Lichtfunktionen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

Kamerafunktion

Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Kamerafunktion

Länderspezifische Varianten

Auch das Nichtvorhandene zählt.

Die Negativprüfung stellt sicher, dass sich nicht verbaute Ausstattungsmerkmale nicht aktivieren lassen. Geprüft wird auch, was fehlen muss.

Safe testing through to delivery

The combination of upstream functional testing and final end-of-line testing enables continuous quality assurance. After successfully completing the final test, the wall-mounted charging station is approved for delivery.

Test methods used and challenges

For functional and end-of-line testing, the system combines programmable power supply and load technology, high-voltage and protective conductor tests, automated signal tests and software-supported process control.

Test software and control

TestManager CE test software

MCD tool monitors for ElectronicLoad, PowerSupply, Serialline, Multimeter, ULC, SerIO and SQL

ULC multifunction card

MIO1616 control unit

High-voltage and load technology

HV adapter of the highest safety class

High-voltage test hood

Safety tester

Programmable AC and DC sources and electronic loads

Safety and functional tests

High-voltage test up to 4.25 kV in accordance with VDE regulations

Protective conductor test at 25 A

Electronically simulated load conditions and pilot-voltage testing

FFT spectrum analysis of the buzzer signal

Application areas

Functional and end-of-line tests on electronic control units and circuit boards

Testing safety-related components

High-voltage tests on electrical assemblies

Protective conductor tests on electrical assemblies in accordance with VDE regulations

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

Optische Prüfungen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Kamerabasierte Erkennung von Lichtfunktionen

Analyse von Spiegelstellungen

Kontrolle des Spiegelglases

Mechanische und elektrische Prüfungen

Antriebe und Klappmechanismen werden mechanisch geprüft, während Winkelpositionen bestimmt sowie Spannung und Stromaufnahme gemessen werden.

Bewegungsprüfung der Antriebe

Winkelmessung der Klappfunktion

Stromaufnahme der Motoren

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

FREQUENTLY ASKED QUESTIONS

FAQS

The end-of-line test system is designed to test wall-mounted charging stations used for charging electric vehicle traction batteries in a domestic environment. These tests cover different product versions in the common power classes from 3.6 to 22 kW.

The EOL test system is used at the end of the production line to ensure that the fully assembled wall-mounted charging stations are completely functional. This includes mechanical, optical and acoustic tests, communication analysis with the charging connector, and safety-critical final tests in the high-voltage range.

In accordance with VDE regulations, high-voltage tests at 4.25 kV, protective conductor tests at 25 A and residual-current tests are performed to check the internal protective switches. This ensures safety during domestic use.

Safety is the highest priority for this manual test system, which is why a multi-stage safety concept has been implemented. It includes special high-voltage adapters of the highest safety class and an integrated high-voltage test hood that prevents direct contact with the unit under test during testing.

By using interchangeable insert solutions in the HV adapter and MCD Elektronik’s modular test software, the systems can be adapted to new designs or future generations of charging stations with minimal effort.

KEY FACTS

Key facts at a glance

Test system

EOL test system / Automated test system / Special-purpose test system

Handling

Semi-automatic / automated

Concept

Single-unit test stand / EOL test station with a single fixture – 1 DUT per test sequence, with HV test hood and interchangeable workpiece fixture

Test methods & test scope

Electrical / HV: 3.6–22 kW power classes, mains voltages, 4.25 kV HV test, 25 A protective conductor test, simulated loads
Communication: Diagnostic interface / charging connector communication
Programming: Writing production data
Optical: LED bar test
Acoustic: Buzzer / FFT test
Temperature: Device temperature test

Components

TestManager CE, tool monitors, ULC, MIO1616, HV adapter, high-voltage test hood, safety tester, AC/DC sources, electronic loads