Parameterization and communication

Unit-specific parameters are written automatically and communication with the DC Energy Meter is verified. Writing unit-specific parameter sets Communication test via RS485 Automated control via the MCD TestSuite Software-supported mandatory sequences for safe user guidance

Electrical calibration and energy verification

Current, voltage and energy are precisely calibrated across the entire test range and verified against reference values. Calibration and testing of direct current up to 1,500 A Calibration and testing of DC voltage up to 1,000 V Comparison of energy against a high-precision reference meter Compliance with a measurement tolerance of ±0.1%

Simulation and response testing

Bidirectional power electronics and automated actuation reproducibly simulate real operating states and user interactions. Simulation of charging and discharging processes with four-quadrant power supplies Reversal of the current direction for realistic charging cycles Automated actuation of buttons on the unit under test Software-based evaluation of the system response

Contact monitoring and documentation

High-current contacts and test results are continuously monitored and fully integrated into the production process. Monitoring the voltage drop at the high-current contacts Checking contact resistance MES integration and automated test logging Automated printing of rating plates or error labels

The e-mobility market will require around one million charging points by 2030

To ensure that DC Energy Meters for charging stations operate precisely and in compliance with calibration law, MCD Elektronik developed a modular test system for comprehensive testing and verification of the devices.

Challenges and concept

EOL testing of Smart DC Energy Meters places high demands on power electronics, measurement technology and process safety. Currents up to 1,500 A and voltages up to 1,000 V must be generated, controlled and measured with an accuracy of ±0.1%. At the same time, the requirements of German calibration law and the European MID Directive must be met.

EnergyMeter_Gafik-Hausverteilung-1600x1200

Blinker, Kamera, Heizung und Assistenzsysteme.

EOLT Systems

Außenspiegel

Smart DC Energy Meters

Modular EOL test system for DC Energy Meters

MCD Elektronik uses the VTS 2030 platform for this purpose. A fully insulated test hood with two contacting units enables the synchronous testing of two units under test. Bidirectional four-quadrant power supplies simulate realistic charging and discharging processes by reversing the direction of current flow.

An integrated safety chain with high-current contactors and the monitoring of voltage drops and temperatures safeguard high-power operation. The MCD TestSuite controls parameterization, testing, evaluation, MES integration, logging and label printing.

Test current

Up to 1,500 A

Test voltage

Up to 1,000 V

Measurement accuracy

±0.1%

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 and functional scope covers all relevant measurement, calibration, simulation and process steps required for reliable EOL validation of the DC Energy Meters:

EOL test stand with two test fixtures

Front view of the test system

Test fixtures, measurement technology and label printer

High-current contacting with copper busbar

Detailed view of the contacting system

Copper busbar and connection components

Wiring in the EOL test system

Detailed view of the system setup

Cables, connection modules and current sensors

Unit-specific parameters are written automatically and communication with the DC Energy Meter is verified.

Writing unit-specific parameter sets
Communication test via RS485
Automated control via the MCD TestSuite
Software-supported mandatory sequences for safe user guidance

Current, voltage and energy are precisely calibrated across the entire test range and verified against reference values.

Calibration and testing of direct current up to 1,500 A
Calibration and testing of DC voltage up to 1,000 V
Comparison of energy against a high-precision reference meter
Compliance with a measurement tolerance of ±0.1%

Bidirectional power electronics and automated actuation reproducibly simulate real operating states and user interactions.

Simulation of charging and discharging processes with four-quadrant power supplies
Reversal of the current direction for realistic charging cycles
Automated actuation of buttons on the unit under test
Software-based evaluation of the system response

High-current contacts and test results are continuously monitored and fully integrated into the production process.

Monitoring the voltage drop at the high-current contacts
Checking contact resistance
MES integration and automated test logging
Automated printing of rating plates or error labels

Bauteilaufnahme im EOL-Prüfstand

Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

EnergyMeter_FCT+EOLT_Spulen+Sensoren (1)-3456x2304

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.

Synchronous testing at high power

Two specially developed contacting units enable the synchronous testing of two DC Energy Meters. The combination of an insulated test hood, high-current monitoring and an integrated safety chain supports a safe test process at high currents and voltages.

Test methods used and challenges

The design of the test system combines power electronics, high-precision measurement technology, high-current contacting and regulatory requirements. The VTS 2030 platform provides the scalable system basis and enables two units under test to be tested in parallel.

Power and measurement testing

DC current measurement from the milliampere range up to 1,500 A

DC voltage measurement up to 1,000 V

Separate measurement paths for low and high currents

Measurement accuracy of ±0.1% across the relevant test range

Simulation and validation

Bidirectional four-quadrant power supplies for charging and discharging processes

Verification of energy against a reference meter

Automated haptic and response tests

Integration of customer-specific software for validating OCMF data records

Safety and contact monitoring

Integrated safety chain with powerful high-current contactors

Continuous voltage drop measurement at the contact points

Monitoring temperatures at the contact points

Guided and monitored process steps in the high-current and high-voltage range

Process and regulatory integration

Automated control and evaluation via the MCD TestSuite

Implementation of the requirements of German calibration law and the MID Directive

Complete test logging via MES integration

Automated label printing after completion of the test sequence

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

These are intelligent direct-current meters that precisely record voltage, current, power and energy in DC systems and provide the measurement data digitally for remote monitoring, control and billing. Their functionality is particularly critical in public EV charging stations because the measured energy consumption forms the basis for correctly billing charging costs.

The EOL test system parameterizes the unit under test by writing specific data to the device memory, calibrates the current and voltage measurements of the DC Energy Meter, and simulates defined charging and discharging currents. OCMF data records are automatically evaluated and verified. Communication with the unit under test, measurement data acquisition and MES integration are fully incorporated into the test sequence.

Testing Smart Energy Meters is particularly demanding because current and voltage must be measured and calibrated with high accuracy across a very wide measurement range. In this system, the test range extends from direct currents in the milliampere range up to 1,500 A and up to 1,000 VDC. This wide dynamic range places high demands on measurement technology, current routing, contacting and the reproducible evaluation of measured values across the entire operating range.

The integrated current transformers allow both very low and high currents to be measured precisely. Four-quadrant power supplies enable operation as both source and sink, allowing the current direction to be reversed deliberately. This enables realistic charging and discharging processes for electric vehicles to be simulated reproducibly while maintaining the required tolerances of ±0.1% across the entire current and voltage range.

Yes. A fundamental requirement during development was ensuring compliance with German calibration law and the European Measuring Instruments Directive (MID). The EOL test system enables exact calibration and verification, which are mandatory for legally compliant billing at public charging stations.

KEY FACTS

Key facts at a glance

Test system

EOL test system / Automated test system

Handling

Manual / automated

Concept

Multi-unit test stand
2 units under test in parallel (synchronously)

Test methods & test scope

Electrical: Voltage, current and power measurement; current and voltage calibration
Mechanical: Button actuation
Communication: RS485, OCMF data verification

Components

MCD TestSuite, MCD tool monitors, VTS 2030 rack system, MCD Controller MIO1616, project-specific high-current contacting, safety controller, emergency stop system, power meter, power supply, mechanical actuation