Column Control DTX

Right Load Switching and Simulation Design for High Current

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In a typical mechatronic manufacturing functional test setup, actual load simulations are usually done by connecting the DUT outputs to power or ground in order to establish either a high or low side driver. Each output is connected with different load and the test will either be sequential or concurrent. At lower power levels, these can usually be managed with general purpose switches. However, when it comes to higher power levels of currents over 5 amps, such switching and loading might pose a greater challenge. Furthermore, critically in the manufacturing line, the tradeoff between cost and test time would have a great influence on the test strategy.

This paper will present some key points to design a cost effective high power switching and load management solution. Firstly, we will discuss the selection process for the types of relays to be used in the switch methodology. Next, for automotive testing where high current measurements are typically done at the output channels, we will look into how this measurement is done; with or without loads and by instantaneous or continuous measurements. Then, we will discuss single load or multi load connections and explore different approaches. These connections provide simulation at different loading conditions. A typical example would be to emulate the steering wheel audio control button with different resistive loads. Subsequently, we will also discuss voltage protection and temperature cooling which are essential in such high power applications. Finally, we will give a bird eye’s view on the complete high level architecture of the combination of switch and load box, where usually the right solution is more than the sum of the parts.

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Column Control DTX