Making reliability measurable – Test bench for safe DC connection technology

1500 V, 40 A DC Test Station

A connector manufacturer needed a test bench for in-house testing of DC connectors under electrical stress. The goal was to simulate mating operations under realistic conditions, detect arcing and reliably manage safety-critical situations such as fire incidents.

AUCOTEAM developed a highly sophisticated test bench for testing DC connectors under electrical load. The mating processes are automated via a linear axis, with speed and electrical load being variably adjustable. During mating, forces are measured, arcs are specifically generated and analyzed using a thermal camera. Thermocouples measure the temperature of the test specimens.

To ensure safety under high electrical loads, the test bench is equipped with safety measures and an integrated fire suppression system. In the event of a fire, targeted ventilation is activated. All test and experimental data are clearly documented.

The test bench consists of an aluminum frame with an integrated control cabinet, power supply racks and a shielded test chamber. Control is handled via an HMI with a touchscreen monitor, which clearly displays safety-related conditions such as fire alarms, door status and emergency stop. The entire design, electrical engineering, and software development were carried out by AUCOTEAM. The integration of the customer’s ventilation system and external fire protection system was also implemented.

Drawing on decades of experience, AUCOTEAM was able to provide a comprehensive, one-stop service for both the design phase and the construction of the test bench. Thanks to its technical design, the test bench can generate defined arcs for testing connectors, while recording the relevant data and ensuring the highest level of safety for personnel and equipment during testing.