Test Bench Master Controller

Project Info:

Main Project:
Inverter Test Bench Project
Client:
Ario MetaPower
Design Completion Date:
2023-09-12
Design Complexity:
The design comprised 90 unique components and a total of 1017 components.

Project Description:

The Master Controller functions as a motherboard for up to ten modules, providing centralised power and control during production or in situ testing of the inverter system.

It can be operated in two modes:

  • Direct control via USB, ideal for production testing
  • Remote control over Wi-Fi via an onboard Raspberry Pi, enabling functional or regression testing while installed in the field

The board features:

  • Five switching power supplies
  • Two linear regulators and a precision voltage reference
  • One adjustable switching power supply (0–24 V) with current measurement and variable constant current protection

The adjustable supply is particularly useful during initial power-up testing of control stack components, acting as a safe and configurable source for the device under test.

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Main Project:

Electron Artz was commissioned by Ario MetaPower to design a flexible, large-scale test bench to rigorously evaluate all inputs, outputs, and subsystems of the inverter control stack during production.

To accommodate potential future changes in the inverter’s design, the test bench architecture was built with flexibility at its core. This led to a modular system based on a Master Controller (motherboard) paired with multiple specialised interface modules.

For testing the inverter control stack, the Test Bench was configured with the following modules:

  • Two modules with 32 Digital-to-Analogue Converters (DACs) each
  • One module with 32 Analogue-to-Digital Converters (ADCs)
  • Two VRail modules, each with 16 power supply load testers
  • One communications module
  • One GPIO module with 40 general-purpose digital inputs and outputs

The system also included:

  • A variable power supply with built-in current measurement
  • An infrared camera interface, enabling safe, gradual power-up of the control stack for thermal and current-draw analysis

This setup made it possible to verify component placement after board population and detect faults early, significantly improving production confidence and system reliability.

Gallery:

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