EOLT Systems
EV wall-mounted charging station
No electric cars without charging stations – and no reliable charging infrastructure without precise test technology
Wall-mounted charging stations for electric vehicles must operate reliably under different mains voltages and current loads. MCD Elektronik therefore developed a test system for a wallbox manufacturer that safely and automatically tests both the electronic circuit board before installation and the fully assembled end device.
Blinker, Kamera, Heizung und Assistenzsysteme.
EOLT Systems
Außenspiegel
EV wall-mounted charging station
During the functional test, the electronic circuit board is contacted via a bed of nails, programmed with the appropriate firmware and tested under stringent safety requirements. Different mains voltages, simulated load conditions, and residual-current, temperature and signal tests reproduce real operating conditions.
In the subsequent end-of-line test, the fully assembled wall-mounted charging station is tested. Electrical connections, communication, controls, LED bars and buzzers are validated automatically. Interchangeable workpiece fixtures and a modular software architecture enable rapid adaptation to new model variants.
The test system combines functional testing of the electronic circuit board with the final end-of-line test of the fully assembled device:
Before installation, the circuit board is identified, programmed and tested under defined electrical and thermal conditions.
- Barcode scan for process interlocking and verification of testability
- Comparison of unit data via the system’s data connection
- Firmware programming
- Testing at different mains voltages
- Functional and load testing
- Checking the pilot voltage under electronically simulated load
- Residual-current and temperature test
- Testing the buzzer signal using FFT spectrum analysis
After assembly, the electrical connections, communication functions and safety-related properties of the wallbox are validated in the final test.
- Barcode scan and comparison of unit data via the diagnostic interface
- Testing at different mains voltages and loads
- Functional and communication test with the charging connector installed
- Checking the pilot voltage under different simulated loads
- High-voltage test at 4.25 kV in accordance with VDE regulations
- Protective conductor test at 25 A
Controls and output signals are tested and production data is finally documented on the device.
- Device temperature test
- Testing the buzzer button
- Functional testing of the LED bars through interaction with the operator
- Writing production data to the unit under test
The test system can be quickly adapted to new wall-mounted charging stations using modular hardware and software components.
- Interchangeable workpiece fixtures
- Modular software architecture
- Rapid conversion for new model variants
- Economical production even for smaller quantities
The combination of upstream functional testing and final end-of-line testing enables continuous quality assurance. After successfully completing the final test, the wall-mounted charging station is approved for delivery.
For functional and end-of-line testing, the system combines programmable power supply and load technology, high-voltage and protective conductor tests, automated signal tests and software-supported process control.
FREQUENTLY ASKED QUESTIONS
FAQS
KEY FACTS
Key facts at a glance
Communication: Diagnostic interface / charging connector communication
Programming: Writing production data
Optical: LED bar test
Acoustic: Buzzer / FFT test
Temperature: Device temperature test
