HIL Tester

Fuse box tester is HIL_ATE system used to validate the UUT which consist of 25 channel of the following current ratings 3A,5A,10A,30A,40A and100A.

Problem Statement

  • Customer wanted HIL_ATE to test each channel for the below loads to observe the UUT efficiency.
      1. Rated load
      2. Programmable loads
      3. Short circuit (HSS channels to GND and LSS channels to Vbat)
      4. Short circuit between the same rating channels. (ex:3A channel will be looped with another 3A channel)
  • Automate the UUT validation using NI Hardware and Software, with the above loads.

 

Challenge

  • Each channel should have a provision for connecting the different loads(loads can sink from 3A to 200A).
  • Single Software Architecture (LabVIEW Application) which can used to validate all the channels.
  • Single test which will validate the path of all 25 channels with all different loads.
  • There are no instruments to measure the current from 3A-200A.

Solution

  • We have chosen SSR and contactors for connecting the channels to different loads based on the rating. (We have used SSR rating from 10A to 150A and for the higher rating we chosen contactor).
  • We have use LabVIEW software to interface with the below software
  • Programmable loads (EA EL loads).
  • Programmable DC supply (Delta power supply).
  • Keysight DMM.
  • We have developed “Dummy UUT” which will source the predefined voltage and current to all the channels and same we are reading back through NI PXI cards and we are comparing the same with the predefined values.
  • We have used LEM sensors to measure the high current.

Impact to Customer

With the development of HIL_ATE-Fuse box tester with LabVIEW software it is possible to connect the different loads to all the UUT channels and control all the instruments connected to the system by LabVIEW.

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