High current and high voltage at the same time challenge end-of-line testing

26 June 2026 | ODU Denmark ApS

• Hardware

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Automated end-of-line testing of converters requires advanced and robust connector solutions. DEIF’s new test bench uses autonomous robots and a custom-designed connector module from ODU and can test 1,000 converters per month.

DEIF in Skive is one of the leading manufacturers of control electronics for energy production. Among other things, the company produces converters at a new production facility designed with the ambition of becoming the world’s best and most innovative electronics factory.

The facility has been built entirely from scratch in collaboration with, among others, GRAU Engineering, an expert in industrial automation solutions. One of the biggest challenges was developing the special machine responsible for performing end-of-line testing of the manufactured converters before they are shipped to the customer.

* The test platform had to handle high current and high voltage simultaneously. This placed very specific demands on the machine, explains Managing Director Kristian Grau.

In addition to safely handling potentially life-threatening currents and voltages, the system also had to manage fiber optics, control current, coolant, and air. Furthermore, the entire testing process had to run automatically, using autonomous robots and automatic connection and disconnection of the test object.

The system needed to be capable of testing 1,000 converters per month across four test stations, with a testing time of approximately 40 minutes per unit.

**High power was the main challenge**

It quickly became clear that the high-power section would be the primary challenge.

The crucial factor was therefore finding a connector module that could automatically connect and transmit up to 1100 A at 1500 VDC, corresponding to a power output of 1.65 megawatts of direct current. At the same time, the multi-connector had to meet all other requirements, including automatic mating. In addition, the complete module had to be supplied by a single vendor.

**ODU offered a solution**

The stringent requirements for the connector module significantly narrowed the field of possible suppliers. It was only when GRAU Engineering contacted Kenneth Pedersen, Mass Interconnect Specialist at ODU Denmark, that a viable solution became apparent.

* ODU has a modular connector system, ODU MAC Blue-Line, which can be combined in countless ways, including for testing purposes, explains Kenneth Pedersen.

* The system also includes high-power modules and hybrid blocks capable of handling high current and high voltage, which can be combined with air, coolant, control current, and more.

**Details required special attention**

Although ODU had off-the-shelf components that met most of the design requirements, certain aspects still required special attention: the high-power module had to be mounted in a floating configuration to enable automatic mating via a MiR robot equipped with a gate from NordModule. Additionally, current transmission was not to be handled solely via cable, but also via busbars.

According to Kenneth Pedersen, this required modifications to ODU’s standard MAC Blue-Line HB16 power block.

Kristian Grau highlights the close collaboration and ODU’s strong commitment to the development process as highly positive. At the same time, it was a major advantage for GRAU Engineering’s designers that ODU took responsibility for solving the technical challenges associated with the automatic connection of test objects. This allowed the engineers to focus on other aspects such as cooling, pumping systems, reservoirs, and more.

**The benefits of modularity**

According to Kenneth Pedersen from ODU, the new converter test platform developed by DEIF in collaboration with GRAU Engineering is an example of what ODU can deliver when it comes to advanced connector solutions for demanding applications.

The solution demonstrates the advantages of the modularity that is the fundamental principle of the ODU MAC product series. This provides optimal flexibility and thereby meets the needs of many of ODU’s customers in functional end-of-line testing.

Modularity makes replacement quick and easy, while also allowing the test setup to be adapted as new versions of products are developed.

Furthermore, Kenneth Pedersen emphasizes that the test platform combines a complex testing requirement—including high current and high voltage—with an automated test process. This combination is advanced and rarely seen, but according to him, it provides an indication of what the future holds in this field.