In Electric Vehicles (EVs) manufacturing, ensuring the reliability and performance of critical components such as Load Distribution Units (LDU) and Power Distribution Units (PDU) is paramount. A leading manufacturer in the EV sector faced the challenge of maintaining high standards of quality and safety while scaling production to meet growing market demands. Hence, we developed a special purpose machine to validate the functionality of LDU and PDU in 160 Parts/Hour.
Specifications
- Simulation of vehicle conditions and component activation
- Modular fixture design for quick transitions
- Utilizing the same fixture for PCBA and EOL
- Parallel testing of UUT(up to 4 UUT simultaneously)
- High current load simulation capabilities
- Electrical safety features for operator protection
- Comprehensive data integration and reporting
Challenges
- Functional Validation: Testing LDUs and PDUs under simulated vehicle conditions to verify responsiveness to critical components such as headlamps, tail lamps, dashboard, horn, and indicators.
- Efficiency in Testing: Transitioning swiftly between PCBA (Printed Circuit Board Assembly) testing and End-of-Line (EOL) inspection to minimize downtime and optimize production efficiency.
- High Current Load Simulation: Simulating loads up to 130 kW to ensure PDUs can handle the rigorous demands of electric vehicle systems.
- Electrical Safety Assurance: Conducting HI-POT (High Potential) testing to detect any potential leakage current or insulation issues at high voltage levels.
- Data Management and Reporting: Integrating sophisticated software systems (SQL, OPC UA, Excel) for comprehensive test reporting and feedback handling.
Features
- Simulation Capabilities: Utilizing a simulation setup to mimic actual vehicle scenarios, including activating various electrical components such as headlamps, tail lamps, dashboard, horn, and indicators. This allowed for thorough functional validation of LDUs and PDUs under realistic conditions.
- Switch Simulation: Emulating vehicle switches (high beam, low beam, indicators, brakes, horn) to observe the response of the UUTs (Units Under Test) under varying loads.
- Efficient Testing Workflow: Implementing a modular fixture design that enabled quick transitions between PCBA testing and EOL inspection. This minimized setup time and ensured continuous production flow.
- High Current Load Handling: Developing capabilities to simulate loads up to 130 kW for PDUs with precise monitoring of parameters such as Power ON, Power OFF, output efficiency, and stability.
- Electrical Safety Protocols: Integrating safety features including light curtains, door switches, and protective shields to safeguard operators during HI-POT testing where voltages up to 1400 volts were applied to check for insulation integrity and leakage currents.
- Data Integration and Analysis: Utilizing SQL databases, OPC UA, and Excel for generating detailed test reports. This facilitated comprehensive analysis of test results and provided actionable insights for continuous improvement in manufacturing processes.
| S.no | Parameter | Value | Comments |
|---|---|---|---|
| 1 | Inspection Speed (LDU) | 160 parts/hour | Based on the sequence to be tested (Automatic or Manual) |
| 2 | Inspection Speed (PDU) | 160 parts/hour | Based on the sequence to be tested (Automatic or Manual) |
| 3 | High current load simulation | Up to 130 kW | Ensure PDUs can handle rigorous demands |
| 4 | HI-POT Testing Voltage | Up to 1400 volts | Detects potential leakage current or insulation issues |
Benefits
- Quality Assurance: Ensuring the reliability and performance of LDUs and PDUs under stringent testing conditions, thereby enhancing overall product quality and customer satisfaction.
- Operational Efficiency:Streamlining testing processes with rapid transitions between testing phases, reducing downtime, and optimising production throughput.
- Safety Compliance:Meeting stringent safety standards with robust safety measures during testing, ensuring a safe working environment for operators.
- Data-Driven Insights:Leveraging data analytics from comprehensive test reports to identify potential areas for improvement in design, manufacturing, and testing protocols.
Types of Defects Identified
- Functional malfunctions
- Insulation issues
- Load handling failures
- Electrical component failures
- Communication failures
Conclusion
The adoption of an advanced testing system for LDUs and PDUs has enhanced product quality and reliability. This case study underscores the importance of rigorous testing and validation processes in ensuring the performance, safety, and reliability of critical components in electric vehicles.