Test Systems
We design and build customized test systems like Hardware-in-the Loop tester and Functional tester optimized for your testing needs. Our test systems support the whole product development cycle from early prototyping to End-of-Line testing in production.
Hardware-in-the Loop (HiL)
Client Case Study: Customized Hardware-in-the-Loop System for Munich Electrification
Client: Munich Electrification, a leading innovator in Battery Management Systems for electric vehicles.
Challenge: Munich Electrification required a specialized, fast, and optimized test system for automated software testing in a realistic, emulated environment. Their goal was to enhance testing efficiency while ensuring system reliability.
Solution: Pass Testing Solutions developed a bespoke Hardware-in-the-Loop (HiL) system tailored to Munich Electrification's specific needs. The HiL system featured two cell emulators with 38 channels, a customized break-out box, and a fault injection box to simulate various failures. The system was uniquely designed to integrate additional client-specific hardware, like pyro fuses and interlocks, enhancing the realism and relevance of testing scenarios.
Key components sourced externally, such as the power supply and industrial PC, were seamlessly integrated into the HiL, controlled by a Python-based testing framework. This approach fostered a transparent and adaptable testing environment, allowing Munich Electrification to easily update and edit the system.
Implementation: The development of the HiL system was a collaborative effort, with constant communication and exchange between Munich Electrification and Pass Testing Solutions. The system, along with all subsystems, underwent thorough in-house testing before being commissioned at the client’s facility. Test cases were jointly defined and implemented, ensuring alignment with Munich Electrification's objectives.
Results:
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Cost Efficiency: The optimized HiL system led to a 20% saving in testing hardware costs.
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Speed and Flexibility: The system was developed and built within just 3 months, demonstrating exceptional agility and responsiveness to client requirements.
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Adaptability: The HiL system's design facilitated ongoing updates and optimizations, aligning with evolving product generations.
Client Feedback: "Pass Testing Solutions supported us in building the perfect test system for our new Battery Management System. The collaboration felt like working with an internal team, characterized by shared goals and high trust."
Long-Term Impact: The initial success of the HiL system led to its continuous evolution, with over 20 systems being built for Munich Electrification. This long-standing partnership underscores the effectiveness and adaptability of the solutions provided by Pass Testing Solutions.
Functional Test System (FCT)
Client Case Study: Innovative Functional Test System for Munich Electrification
Client: Munich Electrification, a leading supplier in Battery Management Systems for electric vehicles.
Challenge: Munich Electrification sought an efficient testing solution for End-of-Line (EoL) production testing. The primary requirement was a system that could seamlessly transition test cases from product development to production, ensuring consistent testing quality while adhering to stringent safety standards.
Solution: Pass Testing Solutions designed a custom Functional Test System (FCT) that emulated the complete environment of the Battery Management System, including battery cells. Key features included:
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Full Environment Emulation: The FCT emulated the battery management environment, ensuring thorough testing.
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Advanced Safety Measures: State-of-the-art safety features were integrated to handle high voltage tests securely.
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Seamless Integration: Utilizing the PTS Test framework, test cases from the HiL phase were effectively transferred to the FCT for End-of-Line testing.
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EMS System Compatibility: The FCT's API allowed full integration with the existing Electronic Manufacturing Service (EMS) system.
Implementation: The FCT's development paralleled the Battery Management System (BMS) creation, fostering knowledge transfer from early testing stages to production. Pass Testing Solutions closely collaborated with Munich Electrification to ensure a smooth transition of test cases from the HiL systems to the FCT. The FCT was jointly commissioned at the BMS manufacturer's site, emphasizing the partnership's collaborative nature.
Results and Impact:
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Test Case Reusability: Key learnings from development were directly applied to EoL testing, enhancing testing efficiency.
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Cost and Time Savings: The emulation solutions and test cases from the HiL phase were reused for the FCT, resulting in significant time and cost reductions.
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Sourcing Efficiency: Off-the-shelf solutions like industrial PCs and fixture mechanics further contributed to the project's cost-effectiveness.
Client Feedback: “The Functional Test Systems provided by Pass Testing Solutions are remarkably flexible and easily adapt to changing requirements. This adaptability allows for direct transfers of changes from product development to the FCT design and testing framework.”
Long-Term Impact: The FCT evolved alongside new generations of Munich Electrification's BMS, continually adapting to new requirements. This ongoing optimization process led to the production of over 7 FCTs, each tailored for use at various EMS locations.