A Testing Application with Unique Challenges
Solar connection boxes must meet demanding requirements for electrical safety, functionality, and quality. Particularly when dealing with a large number of product variants, reliable and flexible testing solutions are essential.
The main challenge of this project was to combine several electrical testing methods within a single system. In addition to high-voltage and insulation testing, the system needed to perform comprehensive functional and continuity tests.
One of the key technical challenges was that high-voltage and functional tests had to be performed at the same contact points.
To achieve this, MCF Technologie developed a sophisticated automated switching system that dynamically connects the required test and measurement instruments to different contact points and electrical potentials, depending on the test sequence.
This flexible switching architecture enables multiple testing methods to use the same product connections without requiring the operator to manually reconnect cables between tests.
High-Voltage and Functional Testing in One Test System
The developed test system combines several testing methods within a single automated process:
High-Voltage Testing (HV): Verification of dielectric withstand strength across different test points and electrical potentials.
Insulation Resistance Testing: Measurement of insulation resistance to evaluate electrical insulation integrity.
Functional Testing (FCT): Verification of the electrical functionality of the solar connection box.
Continuity Testing: Detection of wiring errors, open circuits, and incorrect electrical connections.
The integrated switching system automatically manages the connections between test instruments, contact points, and different test configurations.
Another advantage is the flexible connection of devices under test (DUTs) through interchangeable cable harnesses. This allows different product variants to be tested using the same system.
Integrated Camera Inspection and Intelligent Operator Guidance
In addition to electrical testing, the system features an integrated camera that performs several important tasks during the testing process.
First, it captures images of the solar connection box to document its condition at the time of testing, providing visual evidence of the product's inspected condition before delivery.
Second, the camera enables automatic detection of tripped circuit breakers, allowing these conditions to be identified and considered within the overall test result.
For safe and ergonomic operation, the system is also equipped with a light curtain system to monitor access to the testing area.
An additional display positioned directly at the operator's workstation provides clear guidance throughout the testing process. Required interactions, instructions, and status messages are displayed exactly where they are needed.
Products are automatically identified using barcode scanning, enabling the system to recognize each DUT and select the corresponding test sequence.
kiT.X and Tap.X – Modular Hardware Meets Open Test Automation
This test system is among the first applications developed by MCF Technologie using our new modular kiT.X test system platform.
kiT.X provides a flexible hardware foundation that enables the integration of various measurement instruments, switching modules, interfaces, and automation components.
For software-based test automation, MCF Technologie relies on Tap.X, the test automation platform developed by TapX Software GmbH and based on the open-source OpenTAP framework.
As an official Tap.X partner, MCF Technologie integrates the software into its customized test systems, creating a complete solution for controlling, executing, and documenting complex test sequences.
The open and extensible architecture enables new testing requirements to be implemented efficiently while allowing the system to evolve alongside changing products and production processes.
More Than 100 Product Variants – Managed Independently by the Customer
A key focus of this project is long-term flexibility and scalability.
In the future, the system is designed to support more than 100 different product variants on a single test platform.
What makes this particularly valuable is that the customer does not need to rely on the test system manufacturer for every new product variant or modification to an existing test sequence.
Using Tap.X, the customer can independently create new products, manage product-specific parameters, and develop or modify individual test sequences.
As long as the required hardware capabilities are available, additional product variants can be integrated into the existing test system architecture.
This significantly reduces the effort required to accommodate product changes and provides greater flexibility throughout the system's lifecycle.
Complete Traceability of Test Data and Results
Beyond reliable test execution, comprehensive documentation plays a central role in this application.
The test system is designed to provide complete traceability of test processes and results.
Through unique product identification via barcode, all recorded test data can be associated with the corresponding device under test.
This includes executed test sequences, measured values, test results, and visual documentation captured by the integrated camera system.
As a result, each tested product has a traceable test history that can be used for quality assurance, documentation, and future analysis.
A Future-Ready Solution for Complex Testing Requirements
This project demonstrates how MCF Technologie combines demanding electrical testing methods, intelligent automation, and flexible software architecture within a single integrated test system.
The combination of our modular kiT.X platform, OpenTAP-based Tap.X software, and customized switching and measurement technology creates a solution that not only meets current testing requirements but is also designed to accommodate future product variants.
Are you facing similar challenges in electrical testing or looking to automate your existing test processes?
Get in touch with us. Together, we can develop a testing solution tailored to your products and requirements.
