{"id":40025,"date":"2025-12-03T05:00:00","date_gmt":"2025-12-03T10:00:00","guid":{"rendered":"https:\/\/www.dmcinfo.com\/?post_type=our_work&p=40025"},"modified":"2025-11-25T13:22:57","modified_gmt":"2025-11-25T18:22:57","slug":"end-of-line-test-system-for-power-distribution-unit-subassemblies","status":"publish","type":"our_work","link":"https:\/\/www.dmcinfo.com\/our-work\/end-of-line-test-system-for-power-distribution-unit-subassemblies\/","title":{"rendered":"End-of-Line Test System for Power Distribution Unit Subassemblies\u00a0"},"content":{"rendered":"\n

The client required a single test platform capable of verifying the functionality of multiple power distribution unit (PDU) variants used in a modular battery pack design. Each PDU model featured different input\/output configurations and test requirements, including power input limit testing, discrete signal verification, and hipot validation. The primary challenge was developing a test architecture flexible enough to handle these differences without needing separate test stations for each product. <\/p>\n\n\n\n

\"End<\/figure>\n\n\n\n

To address this, DMC engineered a reconfigurable switching architecture using a Pickering switch matrix and a Pickering high-voltage multiplexer. The switch matrix dynamically adapted the test system\u2019s I\/O configuration to match the specific PDU variant being tested, while the high-voltage multiplexer provided isolation for hipot testing. This configuration enabled safe, automated switching between low-voltage functional tests and high-voltage insulation tests without manual intervention. <\/p>\n\n\n\n

\"Power<\/figure>\n\n\n\n

The test fixture supported up to 20 device-under-test (DUT) pins, 12 of which provide hipot isolation, routed through the high-voltage multiplexer before connecting to the switch matrix. Functional test instruments, including programmable power supplies and DMM channels, were integrated within the matrix, simplifying signal routing and maximizing hardware reuse across different product types. <\/p>\n\n\n\n

On the software side, DMC developed a custom test control application that empowered the client to define and manage their own test specifications and functional sequences. The system also featured MES<\/a> integration, enabling automatic test\u00a0selection\u00a0based on the scanned serial number of each PDU. This\u00a0ensured\u00a0that\u00a0the correct test sequence was executed for every unit and\u00a0maintained\u00a0complete production traceability.\u00a0<\/p>\n\n\n\n

By combining modular hardware design with configurable test software, DMC delivered a flexible, future-proof EOL test solution that simplified production operations and reduced testing complexity across the client\u2019s PDU product family. <\/p>\n\n\n\n

Learn more about DMC\u2019s\u00a0<\/strong>Test & Measurement<\/strong><\/a>\u00a0expertise\u00a0and\u00a0<\/strong>contact us<\/strong><\/a>\u00a0for your next project.<\/strong>\u00a0<\/p>\n","protected":false},"excerpt":{"rendered":"

The client required a single test platform capable of verifying the functionality of multiple power distribution unit (PDU) variants used in a modular battery pack design. Each PDU model featured different input\/output configurations and test requirements, including power input limit testing, discrete signal verification, and hipot validation. The primary challenge was developing a test architecture flexible enough to handle these differences without needing […]<\/p>\n","protected":false},"author":254,"featured_media":40033,"template":"","meta":{"customer":"","summary":"DMC partnered with a client to design and build a functional end-of-line (EOL) test system for a family of power distribution unit (PDU) subassemblies used in a larger battery pack. The project\u2019s key challenge was to develop a flexible and scalable test platform capable of supporting multiple PDU variants, each with unique electrical interfaces and test specifications, while maintaining high test coverage and repeatability. DMC delivered a configurable hardware and software solution that allowed the client to automatically execute the correct test sequences for each product variant, improving efficiency and consistency in production testing. ","description":"","customer_benefits":"