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Project Overview
Multiple projects have been implemented at domestic benchmark automotive groups. With the ongoing evolution and rapid iteration of new energy vehicle charging technologies, super‑fast charging systems have become a key differentiator for enhancing user experience and market competitiveness. The core power conversion modules – namely the AC/DC and DC/DC converters – must undergo high‑intensity, full‑function burn‑in testing prior to deployment, in order to ensure safety and reliability during charging operations. However, traditional manual testing methods – characterised by low efficiency, high energy consumption, and inconsistent data – are no longer able to meet the demands of large‑scale production and quality control.
The current manufacturing processes are primarily confronted with the following challenges:
✅ Insufficient manual operation efficiency, making it difficult to meet rapidly growing capacity demands.
✅ Low standardisation of testing procedures, limiting product quality stability
✅ High energy consumption and labour input, resulting in excessive testing costs.
✅ Lack of process monitoring and data traceability, preventing intelligent management.
To address the above issues, the client plans to build an automated burn‑in test line for super‑fast charging modules. The system employs a conveyor track and test tray configuration to achieve a fully automated testing process – from high‑voltage power‑on testing and burn‑in to final product inspection. Temperature is precisely regulated by a water‑cooling system to ensure stable and safe test performance. This solution will significantly enhance the overall level of test automation and product consistency, building a highly reliable and efficient testing system for the client.
First、Equipment Overview and Core Capabilities
1.Equipment Name / Purpose：Burn‑in test system for NEV super‑fast charging AC/DC and DC/DC modules.
2.Core Objectives：To perform pre‑shipment functional testing of super‑fast charging modules, screening out any functional anomalies.
3.Operating Mode：Utilises a conveyor track and test tray transport system, with automatic docking between trays and test stations during the testing phase.
4.Testing Features：During testing, the modules are cooled via a water‑cooling system with an adjustable water temperature range of 25°C to 80°C.
Second、Test Specifications and Parameters
1.Dimensions：40m (L) × 6m (W) × 2.2m (H).
2.Capacity Configuration：Capable of simultaneously performing three types of testing: high‑voltage power‑on testing, burn‑in, and final product testing.
3.Environmental Control：Ambient temperature.
4.Additional Features：Equipped with fire suppression system to promptly extinguish any smoke or fire hazards during product testing.
This equipment is applicable to manufacturers of NEV battery fast‑charging module products, enabling early failure screening, high‑current cyclic surge testing, unmanned continuous operation, and production capacity enhancement.
Applicable Manufacturers Include:
High‑Power Power Electronics Test Equipment Suppliers：Specialising in high‑power regenerative loads and bidirectional DC power supplies, featuring grid‑connected energy recovery technology.
NEV Charging Facility Test Service Providers：Specialising in comprehensive test systems for off‑board chargers (DC charging stations) and on‑board chargers (OBCs).
High‑Power Density Load Module Manufacturers：Specialising in liquid‑cooled load modules or SiC‑based load modules, addressing heat dissipation challenges at the megawatt level.
Battery Simulator and Energy Storage Test Providers：Leveraging Power Conversion System (PCS) technology to feed electrical energy back to the grid or into energy storage batteries.
Automated Production Line Test Integrators：Integrating high‑power burn‑in equipment into automated production lines, interfacing with Manufacturing Execution Systems (MES) for data traceability.
Consultation
