Test Bench DAC Module

Project Info:

Main Project:
Inverter Testbench Project
Client:
Ario MetaPower
Design Completion Date:
2022-02-23
Design Complexity:
Interesting Stats: The design comprised 50 unique components and a total of 567 components.

Project Description:

The Digital-to-Analogue Conversion (DAC) Module features 32 channels designed to inject accurate voltages into the inputs of the inverter control stack, with 16-bit resolution.

To ensure precision under real-world conditions, the module includes a built-in ADC to monitor the output of each DAC channel. This allows verification of actual output voltages, which may be affected by unexpected loading from the Device Under Test.

Each DAC channel supports configurable output ranges of 0–5 V, 0–15 V, or 0–24 V, enabling flexible simulation of a wide range of input conditions.

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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