High-Density EV Module Burn-in Test System (20 Units/PC)
Mass Production Aging Test System Problem Statement: The client required a mass production testing facility for MXR100030 (30kW) and MXR100050 (50kW) charging modules. The scale involves testing 20 units simultaneously per workstation. The Challenge: The 10-Second Deadline The most critical engineering constraint is the module’s internal Watchdog Timer. If a module does not receive a valid communication packet within 10 seconds, it automatically cuts off the DC power output. With 20 devices flooding the bus with telemetry data, network congestion could easily cause a “Heartbeat Miss,” leading to a failed test and production downtime. Our Solution: High-Throughput CAN Architecture We designed a Multi-Threaded Control Application capable of handling high-density traffic without latency. We moved away from a single daisy-chain loop to a Tree Topology using USB-CAN Hubs to distribute the bandwidth load. ...