A Smart Meter Gateway (SMGW) securely records, processes and transmits energy data in encrypted form to utility companies

For precise billing in compliance with calibration law, MCD Elektronik developed a modular test system for DC Energy Meters. Automated programming and functional testing are performed under high current. Dual test methods significantly reduce cycle times and guarantee maximum quality assurance reliability.
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Challenges and concept

Smart Meter Gateways are the central, BSI-certified communication unit of intelligent metering systems. For series testing, electrical integrity, device operation, encryption mechanisms and safety-related functions must be validated reliably and reproducibly. Parallel test sequences and stable communication throughout the entire test chain are also required.

Smart Meter Gateway HV System_Adapterreihe-offen-1600x1200

Blinker, Kamera, Heizung und Assistenzsysteme.

EOLT Systems

Außenspiegel

Smart Meter Gateways (SMG)

Automated EOL test system for Smart Meter Gateways

MCD Elektronik developed an automated end-of-line test system based on a Raspberry Pi for this purpose. Boundary-scan tests check wiring, component placement and solder joints, followed by functional tests that validate device operation.

Three independent test stations enable parallel test sequences and support high system availability. Centralized control, automation and parallelization create a scalable test solution for secure series production.

Test stations
3
High-voltage test
Up to 3.6 kV
Central control
Raspberry Pi

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

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil
Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Test and functional scope

The EOL test system verifies the relevant electrical, functional and safety-related properties of the Smart Meter Gateways within structured and reproducible test sequences:

EOL test system for Smart Meter Gateways
Overall view of the test system
Three test stations with centralized system technology
Test fixture for Smart Meter Gateways
Detailed view of the test station
Fixture, contacting and test mechanics

Multiple independent test fixtures enable parallel test sequences and support stable series operation.

  • Three independent test stations with separate test fixtures
  • Parallel test sequences
  • High system availability
  • Reduced downtime

Safety-related properties are verified under defined test conditions.

  • High-voltage test up to 3.6 kV
  • Testing dielectric strength
  • Testing safety-related functions
  • Verification of certifiable encryption mechanisms

Structured test sequences ensure functional requirements and consistently high test quality.

  • Reproducible test sequences
  • Ensuring functional requirements
  • Consistently high test quality
  • High product safety

The test solution is designed to scale for modern energy and smart home applications.

  • Centralized control via Raspberry Pi
  • Automated test processes
  • Scalable solution for series production
  • Expandable into automated inline solutions
Bauteilaufnahme im EOL-Prüfstand
Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

smart-meter-gateway-LTE_offeneAdapter-ohneDUT-683x1024

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

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

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

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.

mcd_plus_white
Parallel testing for high system availability

Three independent test stations enable parallel test sequences. This reduces downtime and ensures process stability even when several tests are running simultaneously.

Test methods used and challenges

Testing combines boundary-scan and functional tests with a communication chain controlled centrally via the Raspberry Pi. Stable communication, high process reliability and dependable compliance with regulatory requirements are crucial.

Boundary scan
Testing wiring
Testing component placement and solder joints
Ensuring electrical integrity
Functional test (FCT)
Switching after a successful boundary scan
Performing functional tests
Centralized control via the Raspberry Pi
Communication chain
MCD system sends test requests to the Raspberry Pi
Raspberry Pi issues the test commands
Continuous and stable operation of the entire test chain
Process and safety challenges
Stable communication between the test system and Raspberry Pi
Meeting stringent safety requirements
Handling sensitive data and regulatory requirements
Process stability during parallel tests
Scaling from individual workstations to automated inline solutions
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

It is the central communication unit of an intelligent metering system, usually in the form of a circuit board. It records energy data such as electricity, gas and heat consumption, processes the data and transmits it in encrypted form to grid operators and energy suppliers. It also enables energy systems such as photovoltaic installations or heat pumps to be controlled.
Smart Meter Gateways process and transmit security-critical data and must meet stringent standards as a prerequisite for market approval. Comprehensive testing and complete verification are therefore essential. Only tested devices may be commissioned and sold.
Boundary-scan tests are used to check circuit-board wiring, component placement and solder joints, while functional tests validate device performance. Safety-related tests such as high-voltage and encryption tests are also performed.
The system achieves the customer-specified cycle time of approximately 13 seconds per device and is therefore ideally designed for series production requirements. A Raspberry Pi serves as the central control unit, executes the test software, controls test sequences and ensures that all tests are performed consistently and reproducibly.
The system consists of three independent test stations, each with its own test fixtures. Partially parallel test sequences reduce throughput times and prevent production bottlenecks. Several devices can therefore be tested in parallel, increasing overall productivity and keeping the system operational while individual stations are being serviced.

KEY FACTS

Key facts at a glance

Test system
EOL test system / Automated test system
Handling
Semi-automatic / automated
Concept
Multi-unit test stand with multiple fixtures – 8 devices in parallel / eight-fold fixture, comprising three independent test stations
Test methods & test scope
BSCAN: Boundary-scan test
Electrical: High-voltage test up to 3.6 kV
Communication: LTE, communication signal and encrypted data communication
Functional test: Functional testing of the Smart Meter Gateway
Components
Raspberry Pi, test adapter / HV test adapter, boundary-scan test environment, functional test setup

REFERENZPROJEKTE

EOLT Systems

Smart DC Energy Meters

EOLT Systems

EV wall-mounted charging station

FCT Systems

Smart home systems