CCM Electronic Engineering Aps

Last time updatet: 23/08/2021 13:40:12

Don’t let the unassuming title fool you – this exciting project a part of the latest trends, as the setup will test charging busbars for electric vehicles!  

The sensitive part of the tested component is in fact the adapter box between busbars and the cars battery, which must be waterproof and electrically safe. The tester performs a HiPot test to check the isolation between the cable-cores. The tester operates at 4.3kV DC with an allowable leakage current of 4μA and performs a ground continuity test at 3A between connector housing and the cable shielding.  

The battery connector must be mechanically tested for water resistance using air with a leakage test at 1.5psi. The entire test is performed in one 30 second cycle, which yields high capacity. Further production automation is already in scope and the tester is adaptable into a roundtable solution.  

From a user perspective, the tester is simple and intuitive to use, providing clear results and statistics via a touchscreen and a dedicated LabVIEW software application, and 4 operating modes are available. The machine is built with a focus on user safety, and surfaces are adapted for easy maintenance including lubrication and cleaning that are a part of a quality-assured production.

Last time updatet: 23/08/2021 13:47:48

This project brings us to the frontier of automation as we design a PCB tester which can be operated by a robot. The test station houses an exchangeable fixture, which increases the flexibility and eases the maintenance of the setup. The solution is an update of older hardware.

The test capabilities are severalfold. Firstly, the PCB is identified based on a unique barcode. The programming pins connect to the board and program the unit. Meanwhile, quality inspection takes place as a buzzer is tested to operate correctly using a microphone. Test needles check that the rest of the electronics are connected and operating according to specification. Other testing features include checking output connections to the rest of the product, including voltages on motors and Hall signals.

Collaboration with the customer ensures that the tester will operate as expected and integrate with the existing cell elements.