Automotive Manufacturer Slashes Test Time By 95%

DC-DC Converter Testing

The electrification of passenger cars and commercial vehicles has triggered a shift from traditional 12-volt platforms to high-voltage, high-power DC systems. Across a growing number of e-mobility applications, devices called DC-to-DC power converters are a crucial system component.
In the powertrain of an electric vehicle (EV) or hybrid electric vehicle (HEV), these converters operate at power levels that range from 60 to 180 kW or higher. Elsewhere inside a vehicle, a growing number of “boost” (step-up) and “buck” (step-down) converters are also being used to power the latest advanced driver assistance systems (ADAS) and a variety of safety, comfort, convenience, body, and chassis features.
One of the world’s leading original equipment manufacturers (OEM) of DC-DC converters for EVs and HEVs faced a rapid increase in orders for its higher-power models. These included buck converters that step down high voltages (e.g., 200-300 V) to 48 V for EV and HEV powertrains. Because reliability is an important differentiator for all EV/HEV components, the company decided to replace a mostly manual testing process with a more automated solution that would save time and enhance product quality.

The Challenge

• Reduce DC-to-DC converter test and verification times
• Improve test accuracy consistency
• Replace error-prone manual data logging

The Solution

• Measure multiple parameters using Keysight B2985A meter
• Generate high power levels with Keysight N8900 DC power suypply
• Simplify signal routing with Keysight 34980A switch/measure unit

The Results

• Reduced test time by 95%
• Increased throughput by 4x
• Implemented automated continuous testing to improve overall test efficiency