New Energy OBC Automatic Burn‑In Test Line

Automotive-grade high‑power, high‑precision, and complex operating condition integrated testing; deeply integrated functional safety with full‑chain data traceability; highly flexible and intelligent collaboration.

Product Introduction

The New Energy Vehicle OBC Automatic Burn‑In Test Line is a turnkey, fully automated verification and screening system specifically designed for the core high‑voltage component of new energy vehicles – the on‑board charger (OBC). It integrates high‑power loading, complex operating condition simulation, comprehensive safety monitoring, full life‑cycle data traceability, and automatic loading/unloading functions. It serves as the critical quality gateway for reliability screening (HASS), final performance inspection, and functional verification of OBC products before they leave the factory.

The system strictly follows the principles of the IATF 16949 automotive quality management system and ISO 26262 functional safety. It is designed to actively stimulate and eliminate potential defects by simulating real‑world vehicle usage and extreme operating conditions, ensuring that every product leaving the line meets quality requirements.

Product Features

First Domestic Line

The first domestically designed and successfully commissioned OBC automatic burn‑in test line.
Quality Assurance

1100% automatic testing and data evaluation, eliminating human interference, and rejecting all units with abnormal parameters.
Data Value

The entire process is digitalized and traceable, providing big data support for design improvement, process optimization, and supplier management.
Modular Design

Modular and standardized design ensures high precision in assembly and manufacturing quality.
Energy Feedback

Guanjia's self-developed energy-regenerative load achieves an energy recovery efficiency of over 85%.
Smart Connectivity

Supports industrial Ethernet and multiple communication protocols for easy integration into smart factory systems.

Function Introduction

Function Items

Bi‑directional Energy Regeneration and Load Simulation System

Water Cooling System

Data Acquisition System

Real‑world Operating Condition Simulation and Communication System

Function Description

This is the core energy‑saving unit of the OBC burn‑in line. Unlike conventional burn‑in lines that dissipate electrical energy as heat, it efficiently regenerates the electrical energy back to the internal power grid for recycling through technical means, significantly reducing burn‑in costs.

Since new energy vehicle OBCs predominantly use liquid cooling for heat dissipation, the burn‑in line must be equipped with a water cooling temperature control system capable of supplying and precisely regulating the coolant temperature (e.g., adjustable from 5°C to 85°C) to simulate the actual vehicle cooling circuit.

Independent high‑precision sampling is performed on the input/output voltage, current, and power of each OBC, ensuring high measurement accuracy and data integrity. The system dynamically refreshes and displays the data curve for each burn‑in position in real time. All data (including position code, product code, and test data) are saved in a one‑to‑one correspondence, enabling complete traceability throughout the product life cycle.

The OBC is an intelligent power electronics device that performs complex communication with the battery management system (BMS). Therefore, the burn‑in line must be equipped with intelligent communication capabilities.