Customized Burn-In Test Equipment Solution for New Energy Vehicle Power Supplies

As the core hub of the vehicle energy network, new energy vehicle power supplies include key components such as On-Board Chargers (OBC), DC-DC converters, and Power Distribution Units (PDU), which directly determine vehicle range, charging efficiency, and driving safety.Operating long-term under extreme conditions including alternating high and low temperatures, strong vibration, and high-voltage fluctuations, they require far higher reliability than ordinary power supply products.In response to these characteristics, a customized dedicated burn-in test equipment solution provides full-process support for the reliability verification of vehicle power supplies by accurately replicating automotive scenarios, adapting to diverse components, and complying with industry standards, strengthening the safety baseline for new energy vehicles.

Customized Scenario-Based Working Conditions for Accurate Reproduction of Extreme Automotive Environments

New energy vehicle power supplies must handle complex scenarios including wide temperature cycles from -40℃ to 85℃, multi-axis random vibration during driving, and high-altitude low air pressure, which standard test equipment can hardly fully cover.The customized solution builds a multi-physics coupled test environment tailored to component application scenarios:

• For OBC components, it simulates AC input fluctuations from charging piles, high-power loads under fast charging, and interaction with the vehicle 12V low-voltage network, verifying energy conversion efficiency and stability.

• For DC-DC converters, it customizes high-low voltage switching cycle tests to reproduce sudden load changes during vehicle start-stop, acceleration, and deceleration, evaluating dynamic response performance.

It also integrates dual-85 humidity-heat cycles (85℃/85%RH), salt spray corrosion, and other environmental stresses to fully replicate harsh conditions over the vehicle’s full life cycle, exposing potential defects accurately through accelerated aging.

Customized Multi-Component Adaptation Covering Full Categories of Vehicle Power Supplies

The new energy vehicle power supply system consists of high-voltage power modules and low-voltage control modules, with significantly different testing requirements for different components.The customized solution adopts a modular architecture, flexibly adapting to OBCs from 3.3kW to 22kW, wide-voltage DC-DC converters, and PDU power distribution units, supporting independent single-component testing and multi-component linked aging.

• Following the trend of 400V/800V high-voltage platforms, the solution enhances high-voltage insulation protection with insulation strength up to 10kV or above, equipped with high-voltage surge suppression and short-circuit protection modules to ensure test safety.

• For V2L and V2G functions of bidirectional OBCs, it customizes charge-discharge cycle aging processes to verify the durability of bidirectional energy conversion.

Through interchangeable fixtures and flexible test links, it enables fast switching between components of different specifications, meeting the needs of automakers throughout R&D and mass production.

Integration of Standardization and Personalization for Industry Compliance and R&D Needs

Testing of new energy vehicle power supplies must comply with national standards such as GB/T 24347 and QC/T 895, as well as OEM specifications including Volkswagen VW 80101 and BYD corporate standards.The customized solution deeply integrates standard requirements into test procedures with pre-set standard test modules, supporting one-click execution of compliance tests such as startup inrush current, voltage ripple, and overload protection.

It also provides personalized function customization to address R&D pain points:

• Equipped with an AI data analysis module that collects voltage accuracy, conversion efficiency, temperature rise, and other core parameters in real time, predicting component lifetime (MTBF) through algorithms to support design optimization.

• Integrated with CAN/CAN FD communication modules to simulate the vehicle communication environment, verifying interaction stability between power supplies and ADAS or infotainment systems.

• Compatible with MES systems to realize automatic upload and traceability of test data in mass production, meeting large-scale production management requirements.

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Full-Process Safety and Efficiency Optimization to Help Automakers Reduce Costs and Improve Efficiency

The customized solution focuses on safety and efficiency in vehicle power supply testing.It adopts an active liquid cooling system to precisely control temperature during high-power testing and avoid thermal accumulation affecting accuracy.Multiple built-in safety interlock mechanisms immediately cut off the test circuit and alarm upon abnormalities such as high-voltage leakage, over-temperature, or short circuit, protecting personnel and equipment.

Compared with general-purpose equipment, the dedicated solution shortens the test cycle by more than 30%. By accurately locating weak links, it helps automakers eliminate defective products in advance, reducing after-sales recall risks and costs.Such customized solutions have been widely used in R&D laboratories and mass production lines of new energy vehicle manufacturers, becoming core support for vehicle power supply quality verification.

Future Evolution

As new energy vehicles upgrade toward higher voltage and greater intelligence, testing requirements for vehicle power supplies will continue to evolve.Customized burn-in test equipment solutions will further integrate digital twin, AI diagnosis, and other technologies to achieve more accurate scenario simulation, smarter test processes, and more comprehensive safety protection.They will provide core empowerment for reliability verification of next-generation vehicle power supplies and support the high-quality development of the new energy vehicle industry.