Testing Challenges Faced by the “Energy Hub” of New Energy Vehicles
In the core architecture of new energy vehicles, the Power Distribution Unit (PDU) or Power Electronic Unit (PEU) plays a crucial “energy hub” role. It highly integrates multiple key components such as the On-Board Charger (OBC), DC/DC converter, Microcontroller Unit (MCU), and PTC controller, collectively managing the vehicle’s energy distribution, conversion, and drive.
However, this high integration and functional complexity also present significant challenges to off-line testing in manufacturing and maintenance diagnostics in after-sales service. Traditional separate testing methods using multiple devices are cumbersome, inefficient, and lack comprehensive test coverage, becoming a bottleneck restricting industry efficiency and quality assurance.
Addressing this industry pain point, Guheng Energy, leveraging its deep technological expertise, has launched an innovative integrated PDU/PEU functional diagnostic tester, aiming to provide the industry with a one-stop, high-efficiency ultimate testing solution.
Testing challenges arising from the complexity of PDU/PEU
PDU/PEU: A highly integrated on-board energy management center
The PDU/PEU in a new energy vehicle is not a simple power distribution box, but an intelligent unit integrating multiple power conversion and control modules. Internally, it typically includes:
- On-board charger (OBC): Responsible for converting AC grid power into DC power to charge the battery.
- DC/DC converter: Converts the high-voltage DC power from the battery into low-voltage DC power to supply the vehicle’s low-voltage electrical system.
- Motor driver (MCU): Converts the battery’s DC power into AC power to drive the motor, serving as the vehicle’s power core.
- PTC controller: Manages the high-voltage PTC heater, providing heat for the air conditioning and battery pack.
Each component requires comprehensive verification of its load capacity, conversion efficiency, voltage regulation accuracy, current regulation characteristics, and various protection functions—in-depth functional testing—which goes far beyond simple continuity testing.
Pain Points of Traditional Testing Methods: Split Structure, Inefficiency, and High Cost
In past testing practices, engineers often needed to prepare separate electronic loads, power supplies, test fixtures, and software platforms for components such as OBCs, DC/DC converters, and MCUs. Testing a complete PDU/PEU assembly required repeated device switching, wiring harness connections, parameter settings, and startup testing.
The entire process was time-consuming, complex, demanded high levels of personnel skill, and made unified data management and analysis difficult. In the fast-paced production line testing phase, this model severely hampered efficiency; in the time-sensitive after-sales maintenance scenario, it further slowed down fault diagnosis, impacting customer satisfaction.
One-Stop PDU/PEU Functional Diagnostic Tester
Core Concept: Integrated Design and Optimized Testing Process
Our initial design goal was to replace multiple complex instruments with a single, highly integrated intelligent device. The Guheng Energy PDU/PEU Functional Diagnostic Tester is developed based on this concept. It integrates all necessary components, including a programmable power supply, high-performance DC load, AC analog source, signal generation and acquisition unit, and control logic module, into a single unit. Operation is via a unified 15-inch touchscreen human-machine interface, enabling “one-stop” functional testing of all core components of the PDU/PEU.
Comprehensive Testing Capabilities
This equipment is specifically designed for full-function verification of PDUs/PEUs, supporting precise testing of its four core internal components:
- On-Board Charger (OBC) Testing: It can perform complete load, inverter, current stabilization, voltage stabilization, and charging boot process tests on mainstream OBCs such as 3.3kW and 6.6kW, and supports simulating battery voltage to start the OBC, realistically reproducing its operating state.
- On-Board DC/DC Converter Testing: It can perform load, efficiency, current stabilization, and voltage stabilization functional tests on DC/DC converters from 1.44kW to 3kW, accurately evaluating their conversion performance and stability.
- On-board motor driver (MCU) testing: Enables operational testing and control flow function detection of the MCU.
- Other unit testing: Also allows for testing of bus capacitance and insulation resistance, and verification of the function and control logic of units such as PTC controllers and fast-charging relays.
Highly efficient and flexible testing capabilities
Efficiency improvement is the core value of this equipment. It completely changes the serial, manual switching testing mode:
- Supports single or multiple items and fully automated testing: Users can freely choose to test a single component (e.g., only OBC), or customize a set of test items, and can even start a preset fully automated test with one click. In the automated process, the equipment completes all tests, data recording, and result judgment in sequence, minimizing manual intervention.
- Improved production and maintenance efficiency: On the production line, this automated testing can greatly shorten the off-line testing time, perfectly matching the production rhythm. In the maintenance workshop, technicians can quickly perform a full “check-up” on faulty PDUs/PEUs, and can locate the problem in the OBC, DC/DC, or MCU within minutes, greatly improving the speed and accuracy of maintenance diagnosis.
Intelligent and Convenient Operation and Management
The equipment features a built-in intelligent software system, significantly lowering the barrier to entry:
- Intuitive and Easy-to-Use Interaction: All operations are completed via a 15-inch high-definition touchscreen with a clear interface and explicit instructions.
- Data and Process Management: Supports PDU/PEU IDs via barcode scanning or manual entry, enabling the binding of product information and test data. Test parameters and pass/fail standards can be flexibly set and saved. All test data, results, and curves are automatically saved and easily exported for quality traceability and analysis.
Application Scenarios: Empowering Production and Ensuring Safety
Manufacturing End: Improving the Quality and Efficiency of “Off-Line Testing”
For PDU/PEU manufacturers or OEMs, the Guheng Energy PDU/PEU functional diagnostic tester is a crucial testing link to ensure the quality of outgoing products. It ensures that every assembly undergoes 100% standardized full-function testing before leaving the factory, leaving no potential functional defects undetected. Its highly efficient automated testing capabilities directly reduce testing time, labor costs, and equipment footprint per unit, providing a solid technical tool for enterprise quality control and cost reduction.
After-sales Service: Revolutionizing the “Maintenance” Diagnostic
Model For authorized service centers, large repair shops, or third-party testing institutions of new energy vehicles, this equipment is a highly efficient tool for accurate diagnosis in the face of the increasing number of PDU/PEU – related faults. It avoids the previous blind repair methods of “guessing faults” and “replacing parts to try,” and through scientific and systematic testing, quickly generates authoritative “diagnostic reports,” clearly indicating which component is malfunctioning. This not only improves repair efficiency and first-time repair rate but also reduces the risk of misdiagnosis and spare parts inventory pressure, significantly enhancing service professionalism and customer trust.
Conclusion
The vigorous development of the new energy vehicle industry cannot be separated from the solid support of the reliability of every core component. As the “energy heart” of the vehicle, the comprehensiveness, efficiency, and accuracy of PDU/PEU testing directly affect the performance and safety of the entire vehicle. Guheng Energy, deeply rooted in the new energy testing field and profoundly understanding industry pain points, has launched the PDU/PEU functional diagnostic tester, which is a result of technological innovation in overcoming real-world bottlenecks. We are committed to empowering partners across the entire industry chain, from manufacturing to after-sales service, through this highly integrated, intelligent, and efficient one-stop solution, jointly enhancing the core competitiveness and market trust of China’s new energy vehicles. Choosing Guheng Energy means choosing reliable, efficient, and professional testing assurance.
FAQ
Q: What components can Guheng Energy’s PDU/PEU functional diagnostic tester primarily test?
A: This tester is a highly integrated professional device capable of comprehensively testing the core components integrated within the high-voltage power distribution unit (PDU/PEU) of new energy vehicles. This includes the charging efficiency and performance of the on-board charger (OBC), the voltage conversion efficiency and stability of the DC/DC converter, the inverter and load-carrying capacity of the motor driver (MCU), as well as PTC controllers, fast-charging relays, etc. It truly achieves “one machine, multiple tests.”
Q: How much efficiency does this device improve compared to traditional testing methods?
A: The efficiency improvement is significant. Traditional separate testing requires connecting multiple devices and repeatedly switching wiring and interfaces; testing a complete PDU/PEU can take several hours. Our testers, through their integrated design and fully automated testing capabilities, significantly reduce overall testing time and generally improve efficiency by over 50%. They keep pace with production during off-line testing and enable rapid fault location during maintenance.
Q: Does it support custom test procedures?
A: Yes, the Guheng Energy PDU/PEU functional diagnostic tester is highly flexible. Users can choose to perform single-item tests on individual components or customize and save multiple test sequences in the software based on their product characteristics or maintenance needs. It also supports one-click initiation of preset fully automated tests to meet the diverse needs of different scenarios.
Q: Is the equipment complex to operate? Does it require highly specialized personnel?
A: We are committed to lowering the barrier to entry. The equipment is equipped with an intuitive 15-inch touchscreen human-machine interface, and the pre-set test procedures are clearly defined. Users can learn basic operations after a short training session. The automated testing and report generation functions greatly reduce the reliance on deep technical backgrounds for operators, allowing both production line quality inspectors and maintenance technicians to use it efficiently.
Q: How is test data managed?
A: The equipment has a comprehensive test data management system. It supports product ID scanning and automatically binds test data to products. All test results, process parameters, and curves are automatically saved in the device and can generate reports, which can be easily exported via USB flash drive, greatly facilitating product quality traceability, statistical analysis, and maintenance record management.
