The end-of-line inspector uses multiple methods and tools to test samples so that any defects are detected before they reach the user. Through these methods, quality control not only increases the reliability of products, but also makes the production process more efficient, minimising the number of recalls and warranty repairs. EOL testing is therefore not only a technical step but also an important strategic element in maintaining competitiveness in the market. In this article, we will describe the process of final tests on electronics production lines.

The concept and purpose of EOL testing

EOL (end-of-line) testing is the final step in the manufacturing process, where finished products are subjected to detailed testing. This type of final testing ensures that onboard chargers meet stringent quality and performance requirements before they are delivered to customers. EOL testing is a time-consuming and complex process that uses multiple test equipment and measuring instruments.

Final testing plays a key role in the manufacturing process, providing an opportunity to detect potential defects in the products. Defects such as performance anomalies, mechanical failures or communication problems can be detected and corrected before they reach the user. Final inspection both ensures product quality and enhances the company's image, as the delivery of defect-free products increases customer confidence and satisfaction. During the process, various tests are performed, such as full load operation, temperature tests and simulation of power faults. These tests provide a comprehensive picture of the condition of the products and guarantee their long-term reliability.

Final inspection tests

Functional tests

Functional testing validates the operation of the device. Tests may reveal manufacturing-related malfunctions, such as poorly soldered components or assembly and development, and design inaccuracies in both electronics and software.

Load tests

During load tests, onboard chargers are subjected to maximum load. This full load test verifies that the charger can function as intended in the real environment. Apart from examining the optimum parameters, the long-term reliability of the charger is also checked. We also test the standby unit operations, confirming that they remain stable in standby mode with minimum power consumption. This is particularly important for efficiency and energy consumption.

Network tests

During network testing, we simulate a variety of input parameters. We test different voltage ranges to make sure that the onboard charger will work reliably under different mains conditions. We also simulate variations in input to see how the charger reacts to various power sources.

During the battery simulations, we investigate several battery conditions such as discharged, charged or faulty batteries. This ensures chargers accurately detect and handle different battery conditions, protecting the car and the user from potential problems.

Temperature tests

During thermal tests, onboard chargers are exposed to low and high temperatures to simulate the different environmental conditions they will face in real life. Such tests ensure chargers work reliably even in extreme temperatures, whether in hot desert environments or cold winter weather.

In mass production, burn-in testing is important to verify the durability and reliability of products. During these tests, the chargers are usually run at high temperatures for long periods of time to detect potential faults sooner and ensure that the devices will meet expectations.

To summarise, the load, power, temperature and functional tests ensure that the onboard chargers meet the highest quality standards.

ProDSP EOL tester for on-board chargers

The EOL (End of Line) tester for onboard chargers developed by ProDSP is a sophisticated and versatile tool that plays a fundamental role in the end-of-line testing process. This tester offers outstanding features that enable the detection of possible defects in onboard chargers before they leave the production line.     

Its primary purpose is to perform functional and burn-in tests to ensure that products will continue to operate reliably over the long term. The tester allows the simulation of a wide range of input parameters to ensure chargers work properly at different voltages and frequencies. It can be operated in both low and high-temperature conditions, ensuring that chargers can withstand the widest possible range of environmental conditions.

In load tests, the tester can simulate the operation of the chargers at full load and on standby. In mains simulations, it can mimic different battery conditions - whether discharged, charged or faulty - and simulate the influence of multiple faults.

Additional features of the EOL tester include support for communication interfaces such as CAN and LIN, as well as customizability to meet specific communication needs. Data can be logged at both high and low frequencies so that all relevant parameters can be continuously monitored and analysed.

The user interface is easy to use both during operation and maintenance, further increasing the efficiency of the device. CE marking ensures that the tester is fully compliant with industry standards.

The ProDSP EOL tester is an indispensable tool for comprehensive final testing of onboard chargers, contributing to the long-term reliability and high quality of products.