The customer's problem
A Tier 1 supplier is developing a new generation of high-voltage connectors for use in electric powertrains. For design and production approval, robust evidence was required regarding current-carrying capacity (including derating), mating cycles and locking mechanisms, IP protection ratings, as well as resistance to environmental conditions, corrosion, UV exposure, media and mechanical stress. The documentation had to be standards-compliant (including LV 215 and relevant parts of the DIN EN 60512 series) and fully traceable—all while meeting a tight schedule and accommodating multiple variants.
Solution by AUCOTEAM
AUCOTEAM performed the validation on a modular "Heart-of-Test" rack. The system combines a high-voltage safety concept, time-synchronized data acquisition and standardized interfaces to climate/temperature chambers, water cooling and shakers. The test setup allowed for up to six current paths, conductor cross-sections up to 360 mm², voltages up to 1,000 V and currents in the range of approximately 1,000 A per path. Data collected included 12 galvanically isolated voltage drops up to 1,000 V and 12 temperature channels. CAN/LIN bus protocols were integrated into the test logic. The sequences ran automatically with limit value monitoring and soft safety.
The derating curves were determined in two chambers in accordance with DIN EN 60512-51/-52, including hot-spot validation via thermal imaging. The environmental tests included climatic tests, salt spray, solar simulation according to DIN 75220, IP protection rating tests, chemical resistance, vibration and shock. In addition, ice water immersion tests, splash water tests, and functional tests under load were performed. Deviations were evaluated using trend analyses of contact resistance. All measurement data are auditable and traceable. The project was completed in 2022.
Key Features of the AUCOTEAM Solution
- Quick campaign launch: reusable test rack, preconfigured measurement chains, short setup times
- Parallel validation of multiple variants with identical setup for robust A/B comparisons of contact geometries and materials
- Complete derivation of derating curves, including hot-spot analysis, boundary case consideration and documented measurement uncertainty
- Environmental and IP testing from a single source: climate, corrosion, UV/sunlight, media resistance, vibration/shock, splash water and ice water immersion
- End-to-end traceability: automated reports, serial number tracking, structured photo documentation, test bench-integrated data management
- Flexible bottleneck solutions: from on-demand testing to temporary in-house rental of infrastructure and personnel
