Programming and Electrical Measurements

Assemblies are programmed and their key electrical parameters are recorded under different operating conditions. Programming the assemblies Voltage measurements up to 1,000 V Current measurements Output power measurement

Load, High-Voltage, and Functional Tests

The power supplies are tested under high electrical loads, and safety-relevant operating states are verified. Load tests in the kW range Short-circuit and high-voltage tests Analysis of shutdown behavior Controlled discharge of the assemblies

Signal and LED Testing

Dynamic signals and defined LED functions are captured and evaluated during the test sequence. Signal analysis with an integrated oscilloscope Monitoring of electrical signal profiles LED tests Testing of defined flashing functions

Process Integration and Variant Flexibility

Automated process steps and flexible adaptation support efficient use in production. Automated label printing Connection of measurement data to the MES system Flexible adapter and changeover system Rapid adaptation to different power-supply variants

MCD Elektronik develops test systems for constant current supplies in LED modules

MCD Elektronik develops test solutions that reliably and repeatably test LED power supplies even under demanding HVAC/HVDC conditions. This specifically safeguards key requirements for the service life, safety, and efficiency of modern lighting systems, including applications in aviation, stadiums, railway stations, and television studios.

Challenges and Concept

Automated functional testing of constant current LED power supplies places high demands on electrical load capacity, high-voltage safety, and repeatable test conditions. The assemblies must be tested reliably under realistic operating conditions, and their function and stability at high voltages and loads must be verified.

FCT LED power supplies_mcd-005-1600x1067

Blinker, Kamera, Heizung und Assistenzsysteme.

FCT Systems

Außenspiegel

Constant Current Supplies for LED Modules

Automated Functional Test System for LED Power Supplies

MCD Elektronik developed a functional test system that automatically performs electrical functional and endurance tests under realistic operating conditions. The test scope includes short-circuit and high-voltage tests, output power measurement, and analysis of shutdown behavior.

A modular adapter and changeover system enables repeatable testing of different power-supply variants with minimal conversion effort. The test solution therefore supports safety-critical aerospace and defense applications as well as demanding infrastructure and high-performance lighting applications.

Voltage Measurement

Up to 1,000 V

Load Range

kW range

Measurement Data Connection

MES system

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 %

Testing and Functional Scope

The FKT system verifies the relevant electrical functions, performance parameters, and safety features of constant current supplies for LED modules under defined test conditions:

Test fixture with transparent protective cover

Top view of the test fixture

Assembly fixture and contacting

High-voltage test station with protective hood

Overall view of the test setup

Protected test area with operator unit

Test station with closed protective cover

Side view of the test station

Protective enclosure and test fixture

Assemblies are programmed and their key electrical parameters are recorded under different operating conditions.

Programming the assemblies
Voltage measurements up to 1,000 V
Current measurements
Output power measurement

The power supplies are tested under high electrical loads, and safety-relevant operating states are verified.

Load tests in the kW range
Short-circuit and high-voltage tests
Analysis of shutdown behavior
Controlled discharge of the assemblies

Dynamic signals and defined LED functions are captured and evaluated during the test sequence.

Signal analysis with an integrated oscilloscope
Monitoring of electrical signal profiles
LED tests
Testing of defined flashing functions

Automated process steps and flexible adaptation support efficient use in production.

Automated label printing
Connection of measurement data to the MES system
Flexible adapter and changeover system
Rapid adaptation to different power-supply variants

Bauteilaufnahme im EOL-Prüfstand

Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

FCT LED power supplies_mcd-002 (3)-3000x2000

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.

Flexible for Different Power-Supply Variants

The high-voltage adapter with a flexible changeover system enables repeatable accommodation of different test specimens with minimal conversion effort. This allows the FKT system to be adapted efficiently to different variants.

Test Methods and Results

For testing LED constant current supplies, the FKT system combines electrical performance and high-voltage tests with signal analysis, flexible adaptation, and monitored safety functions.

Electrical Performance and Functional Tests

Load tests in the kW range

Voltage and current measurements

Output power measurement

Analysis of shutdown behavior

High-Voltage and Signal Analysis

Short-circuit and high-voltage tests

High-voltage multiplexer and power meter

Signal analysis with an integrated oscilloscope

Frequency converter for defined test conditions

Test Software, Adaptation, and Control

TestManager CE test software

Tool monitors for electronic load, power supply, interfaces, and measuring instruments

High-voltage adaptation with flexible changeover system

MIO1616 for controlling contacting, adapter locking, and contactors

Safety and Process Stability

Independent emergency shutdown circuits

Insulation monitors for monitoring the safe operating state

Safe routing of all supply lines beneath the work surface

Defined safety conditions for operating the test station

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

Constant current supplies, also known as constant current power supplies, provide high-intensity light sources with sustained output and low power consumption. Applications include lighting systems for parking areas and railway stations, floodlighting for sports venues, and television studio lights.

The FKT (functional test) system is used during PCB production. It monitors electrical functions, performs high-voltage, endurance, and short-circuit tests, and checks the current behavior and power output of the supplies. Test results, voltages, currents, and test-specimen behavior are documented at the end.

Testing is performed under realistic HVAC/HVDC conditions so that the behavior of the constant current supplies can be validated under practical, sustained operation.

The system uses input voltages up to 600 V, output voltages up to 1,000 V, and power levels up to 20 kW. Special high-voltage multiplexers, insulation monitors, and HV adapters are used for this purpose.

Modular adapter and changeover systems, with their supply lines routed beneath the work surface, allow different LED power-supply variants to be tested.