Optimal Testing Guaranteed
Sonplas: Test rack accelerates the design of test systems for power electronics.
Sonplas provides complete turnkey systems that not only automate the assembly of power electronics components
for electric and hybrid vehicles but also perform comprehensive testing. To enhance the efficiency of designing test
systems, the special-purpose machine manufacturer has developed a modular solution within its electronics laboratory.
This enables the necessary customer-specific measurements to be conducted and analyzed in advance, ensuring that
test systems are perfectly tailored to the customers’ needs. As a result, customers receive their customized solutions
even faster – with seamless operation from the very start.
“With our new test system, we help our customers develop fully customized systems that enable them to efficiently test components such as inverters, on-board chargers, and DC/DC converters in their production processes,” says Alexander
Denk, Team Leader of Electrical Design at Sonplas. They benefit from faster project planning and the resulting cost savings. Before installation at the customer’s site, Sonplas experts evaluate which measurement methods can be applied and whether they yield the expected results. Endurance tests, current and voltage measurements, as well as performance and efficiency testing, can be conducted. Initial estimates of cycle times, along with evaluations of the final software and hardware suitability, are also features of the test rack.
left: Modular Testsystem from Sonplas for components in power electronics which makes ist possible to carry out essential measurements in advance.
right: Test-Rack for high-voltage applications (up to 1500V / 15kW) and low-voltage applications.
Sonplas customizes the test system according to specific requirements. In order to achieve this, the special-purpose machine manufacturer utilizes a modular system consisting of various measuring devices, safety analyzers, and a high-voltage power supply. The test system meets all necessary safety requirements, e guaranteeing a
secure testing process for the user at all times. “Our test system can operate at voltages of up to 1,500 volts,” says Anton Lettl from the Sonplas sales team. “This ensures we are prepared for future systems, as current onboard networks still operate at 800 volts.”
Since Sonplas can support both low- and high-voltage applications during the development phase, the special-purpose machine manufacturer provides not only functionality but also the required safety of the components from the outset. Another
key feature of the system: Even after installation at the customer’s site, Sonplas experts can optimize the setup without disrupting or halting production.
“Since we can measure various test objects, the new system is also well-suited for prototype validation,” explains Alexander Denk. This helps reduce development times
for customers while providing valuable insights for optimization. “We ensure that all
tests meet customer requirements and that the tested product complies with the
highest quality standards,” adds Anton Lettl. The new test system has now become
an integral part of the Sonplas electronics laboratory in Straubing.
