Power Electronics Test

Power Electronics Automated Test Solutions

Power Electronics Automated Test Solutions are designed for AC/DC, DC/DC, power modules, SMPS, power conversion and power electronics control modules. The system integrates programmable sources, electronic loads, DMM, oscilloscope, power meter, switch matrix, custom interfaces and test software into a complete automated test system.

Customer Challenges

  • Power electronics testing often involves input conditions, output load, voltage, current, power, waveform, protection, dynamic behavior, isolation and burn-in.
  • Manual testing requires operating multiple instruments, complex steps, error-prone configuration, scattered results and inconsistent production takt.
  • Different power product models require different test sequences, limits, instrument setup and reports.
  • High-voltage/high-current and isolation-related tests need to be executed under controlled conditions.

Solution Approach

  • Build a test software flow with test executive, sequence, instrument control, configuration, pass/fail and report/data.
  • Integrate AC source, DC source, electronic load, DMM, oscilloscope, power meter and switch/matrix resources.
  • Connect DUT through switch/matrix, fixture and custom interfaces to form a configurable power test platform.
  • Build test sequences for input, output, dynamic load, protection, high-voltage isolation, burn-in and data recording.
  • Use the 4kW Power Supply ATE, CVS and OBC cases as project evidence without duplicating full case content.

Core Capabilities

Input voltage variation, line regulation, voltage sag and over/under-voltage behavior verificationOutput voltage, output current, load regulation, ripple and PARD testDynamic load test and load-change response captureControlled overload, short-circuit and over/under-voltage verificationHigh-voltage and isolation test integrationBurn-in test flow and data loggingDMM, oscilloscope, power meter, electronic load and switch matrix integrationHigh-voltage/high-current test engineering, calibration, fixture and interface design

Deliverables

  • Power electronics automated test software and sequences
  • Integration of AC/DC source, electronic load, DMM, scope, power meter and switch matrix
  • Input, output, dynamic load, protection, isolation and burn-in test flows
  • Custom interface board, relay/switching, signal conditioning, load interface and fixture electronics
  • Test results, reports, configuration and production data records
  • On-site commissioning, operator training and maintenance documentation

Business Value

  • Reduces operator variation through sequence automation, instrument coordination and repeatable configuration.
  • Combines power source, load, measurement, switching, control, fixture, test software and data into a complete test system.
  • Supports a universal power test platform concept with common test architecture, configurable sequence and model configuration.
  • Supports production quality analysis and engineering maintenance through automatic judgment and data recording.

Specifications

Applicable Products
AC/DC converter, DC/DC converter, SMPS, power adapter, telecom power supply, DC power module, high-current power module, UPS / inverter and automotive power electronics
Typical Resources
AC/DC source, electronic load, DMM, oscilloscope, power meter, switch matrix, fixture, custom interface board and test software
Project Evidence
Universal 4kW Power Supply ATE, CVS high-voltage/high-current test and OBC PCBA functional test
Important Note
0-4kW, 0-320VAC, 0-800VDC, 850VDC and +/-700A come from project scope or project experience, not onTAP general capability limits.

Planning a power electronics automated test system?

onTAP can start from product test items, instrument resources, load conditions, fixture interface, test software, reports and production data to build maintainable power electronics ATE platforms.

Contact onTAP