Test Systems for Wall Charging Stations

Owners of electric cars are able to install charging stations for the loading of their vehicles' traction battery at their own garage. These wall charging stations have the benefits to load the vehicles' battery a lot faster, thereby being more energy-efficient and without complicated wiring compared to standard domestic sockets. MCD Elektronik developed a test system for the testing with various current loads for a well-known manufacturer of these charging stations. This results in that the approved product is usable in different variants for power classes from 3,5 kw up to 22 kW.

The FCT station performs functional tests and programming efforts at the control PCB of the product, while the EOLT station tests all quality relevant characteristics of the final product, meaning, the integrated PCB inside the housing. After a positive test result, an appropriate label is printed and the product cap is screwed onto the housing. The wall charging station is now ready for delivery.

Features:

  1. Functional test

    • Barcode scan for process interlocking and for verification of the DUT's testability
    • Comparison of testing data via connection with the system
    • Firmware programming
    • PCB testing under different supply voltages
    • Functional and stress test
    • Verification of pilot voltage and functionality under electronic simulated loads
    • Residual current test
    • Temperature test
    • Buzzer signal test with FFT spectrum analysis

  2. End-of-Line test

    • Testing of the finally mounted terminal, where the pre-tested PCB is installed
    • Barcode scan for process interlocking and for verification of the terminal's testability
    • Comparison of testing data via connection with the system via diagnostic interface
    • Wall charging station testing under different supply voltages and loads
    • Functional and communication testing with mounted loading plug
    • Verification of pilot voltage and functionality under various, electronic simulated loads
    • High voltage test with 4,25 kV in accordance with VDE regulations
    • Protective ground test with 25 A
    • Temperature test of the complete device
    • Buzzer button test
    • Writing of production on the DUT
    • Functional test of LED strips by interaction with the user
    • Device is ready for customer delivery after these final tests

Equipment components:

Application examples:

  • Functional and End-of-Line tests of electronic control units and PCBs
  • Functional and End-of-Line tests of safety relevant components
  • High voltage tests of electronic assemblies
  • Protective ground tests of electronic assemblies in accordance with VDE regulations