End-of-line test field for inverters

This inverter test field was developed for a German automotive manufacturer and integrated into the existing production line layout over the course of an 18-month project, taking into account the client’s specific requirements. Leak testing or customised sensor calibration can be seamlessly integrated into the automated product inspection, tailored to specific requirements. The process is further streamlined by an advanced data handling solution. With a cycle time of just 30 seconds, the system ensures high output— a crucial factor for the client’s competitiveness in the automotive market.

Leak testing is one of JW Froehlich’s core competences. To start with, the inverter’s interior and the coolant container are tested for leaks.

To keep the cycle time to a minimum, the flash test, sensor calibration, load test and HV test are carried out simultaneously in independent stations.

To achieve a reliable end-of-line test, the electric drive is emulated using an active or passive load. The HV measurement determines the test part’s voltage strength and insulation resistance.
The various measurements provide a wealth of data that is collected, evaluated and stored according to the necessary security aspects. The client has listed cybersecurity as a special requirement, and the data handling has been customised to meet those needs.
The final step of the load test involves screening in a climate chamber, utilising a conditioning unit with a temperature range of -30°C to +65°C.