Free Power-Workshop: Testing of energy storages & power products

16.04.24 Köln | 17.04.24 Hannover | 18.04.24 Leipzig | 19.04.24 Nürnberg


E-Mobility: Function, Safety and Performance Tests for Charging Cables and Wall Boxes

Intelligent Charging Cable: Test Strategy and Test Execution

Application Description

The ICCB takes over the safety and control functions that are otherwise integrated in the stationary charging station. This places increased demands on the function test in production.

Test strategy: Separate function tests for the “operating and control unit” module and the “power electronics”.                 

The test of combined assemblies usually includes separate pre-tests of the two assemblies as well as the EOL test after assembly. During the functional test of the electronics, the power supply is first checked and the test firmware is programmed. Furthermore, the “internal electronics”, voltages at test points, interfaces such as I2C, SPI, CAN... as well as radio interfaces such as WLAN, Bluetooth are tested.

As instruments for functional testing of the control modules are often used:

  • DC voltage sources with current monitoring
  • JTAG programming devices
  • Test firmware and boundary-scan HW
  • Multiplexer/matrices for switching the test points to the measuring instruments
  • Multimeter/oscilloscope/counter
  • Test interfaces for I2C, SPI, CAN
  • Coupling antennas and RF power meters or corresponding remote stations

Frequently performed tests of power electronics:

  • Safety or insulation test with HV (5 contacts network to 5 contacts vehicle as well as test RCD/FI protection)
  • Communication test e.g. Powerline
  • Performance test AC e.g. 3kW, 11kW, 22kW, 42KW and optional DC 10kW-100+ kW

Special Features

Use of automated actors with finger imitations for testing capacitive touch-displays.

System Type
Employed Technology
Image Processing / LED Evaluation
Swithing of High DC Voltages and Currents
Switching of Voltages >300V
DUT Programming (JTAG) etc.
  Embedded Controller by LX
Serial Communication
Standard Software
LX-TSCOE4 Operator Interface...
LX-Test Database...
LX-Magpie Evaluation Software...
LX-Woodcreeper Database API...
  NI TestStand...
Keysight TestExec SL...
  Associated Research Autoware
LX-Test Step Library
  NI LabVIEW...
Keysight VEE...