April 25, 2025 Reliable Power Electronics Components Testing

Alongside assembly systems, Sonplas also offers extensive expertise in testing.

The power electronics in electric and hybrid vehicles is improving all the time. In order for manufacturers to remain competitive at this high level, they require systems that not only allow them to safely assemble the individual components – inverters, chargers and DC/DC converters – but also to test them. Sonplas delivers everything from a single source. As a partner, we offer our customers comprehensive expertise, develop innovative systems, and proudly showcase our successful references.

The complete propulsion system of an electric vehicle is regulated by power electronics. It comprises three components, with the first being the inverter. Its primary function is to convert the DC voltage from the battery into AC voltage required for the motor. The second component is the AC charger, often referred to as the charging unit. When refuelling at the socket or wall box, alternating current flows, which this component converts into direct current, thereby charging the battery. Additionally, there’s the DC/DC converter, responsible for supplying power to the 12 V vehicle electrical system, among other functions. “These components are intricate assemblies,” explains Alexander Denk. As the electrical design team leader at Sonplas in Straubing, Lower Bavaria, Alexander Denk is well-versed in the current challenges confronting manufacturers, OEMs (original equipment manufacturers), and Tier 1 suppliers. “Power electronics stands as a pivotal technology for the successful evolution of the automotive industry. Innovation cycles are becoming ever shorter. “This increases efficiency, while power losses decrease at the same time.” Companies need to be capable of adjusting to this. However, as Denk points out, this is no easy feat. That’s because they often lack the time that is necessary. Furthermore, there is a shortage of skilled labour. As a result, they often lack the essential knowledge to successfully drive developments forward.

All-in-one solutions

As a specialised machinery manufacturer, Sonplas delivers assembly and testing systems tailored specifically for this sector, always in close collaboration with the customer. “We design and implement line concepts for inverters, converters, and on-board chargers, ranging from prototype construction to high-performance systems with cycle times spanning from 20 to 300 seconds,” explains Alexander Denk. “Users can utilise it to manufacture typical components ranging from two to 25 kilograms in weight.” Depending on project requirements, the experts leverage a wide portfolio of tried-and-tested, and in some cases patented, processes – or they collaborate with the customer to develop customised solutions tailored to their needs. This allows them to substantially decrease their production costs. Denk: “With our extensive experience in electronics production, we also develop and manufacture power amplifiers in our own laboratory, for example.” Sonplas also offers assistance in prototype construction for companies that lack the necessary equipment to produce them in-house.

The power electronics components that are manufactured must then undergo testing. It is important that this process is adapted to suit the respective requirements precisely. However, this often entails a significant amount of work for manufacturers. Moreover, most suppliers of assembly systems do not provide testing services themselves. Either they lack the expertise or they lack the necessary equipment to fully conduct the required tests. As a reliable partner, Sonplas has rapidly acquired extensive expertise and now proudly boasts numerous highly successful references. “Customers trust our specialists, relying on their experience, comprehensive advice, and assessments.” This gives them clear added value,” explains Denk. As a partner, the Straubing-based company offers users significant assurance during the frequently uncertain development phases.

Individually customizable thanks to its modular design

The test systems for the EOL (end-of-line) area have a modular design. This enables the machine manufacturer to flexibly customise them according to individual requirements. Depending on the application and the specific testing needs, the experts assemble the modules from the modular system accordingly. The customer receives a basic machine with the suitable test adapter for various product types, thereby saving significant costs. Depending on the requirements, the machine can, for example, conduct leak testing, typically performed using air, or it can perform flashing to store calibration data or install the operating system. Customers also use the test station to test communication via CAN or Ethernet, for example. Alexander Denk: “They can measure and calculate currents, power, and efficiency, and indirectly determine the speed.”

Manufacturers also benefit from reliable solutions for safe-launch tests , as well as for cold and hot testing of circuit boards or entire assemblies. In order for electric and hybrid vehicles to operate at an optimal level of efficiency, it is essential to maintain the temperature of not only the electric motor and the battery within an optimum range, but also that of the power electronics. “With our systems, operators can conduct tests ranging from minus 40 to plus 90 degrees Celsius.” “They are also capable of simulating various environmental conditions,” explains Denk. It is also possible to conduct long-term tests  prior to planned series production. The products undergo even more rigorous testing.

Safety is the top priority

“Our systems can also accommodate all voltage ranges,” assures the Sonplas expert. This is due to electric vehicles having two electrical systems: the high-voltage system for the drivetrain and the low-voltage system for on-board electronics such as the radio, lights, windscreen wipers, and cruise control. For this purpose, a high-voltage battery is installed, which can supply power to the 12-volt battery for the onboard electronics via the converter. “In the past, the voltage became higher and higher,” says Denk. “In the beginning, it was only 48 volts; now it’s 800 volts. The trend is even moving towards 1,200 volts,” he adds. This is because more and more power is required for the same amperage. The systems must be capable of safely handling both current and future higher voltage values. Numerous tests are conducted directly on the live components of the power electronics. After the test specimens have been tested, it must be ensured that they are no longer energized when the worker opens the safety door. Otherwise, it could pose a life-threatening risk for them. Alexander Denk adds: “We offer a concept that addresses potential causes of accidents and minimizes risks.” “This begins with the selection of appropriate installation materials, such as cables, terminals, and other components and materials.” Just as safely and effectively as they manage high voltages, the systems also handle peak currents exceeding 800 amperes, resulting in correspondingly high outputs.

Full-service character in perfection

Sonplas offers assembly and testing solutions from a single source. The specialized machine manufacturer efficiently integrates both disciplines into its solutions. With a proven network of carefully chosen and dependable partners, users receive a comprehensive package and interact with just one point of contact. This streamlines the process, minimizes organizational overhead, and circumvents interface issues. “Of course, we also provide training to our customers on our systems,” explains Sonplas expert Denk. Utilizing modular construction, the experts also customize the test stations to meet growing demands or accommodate modified products. Denk: “We assist the operators with our wealth of expertise.”

Sonplas continuously evolves through ongoing dialogue with customers. To anticipate trends proactively, specialised machine manufacturers consistently listen to the market and strive to stay ahead with innovative solutions.

Further information: https://www.sonplas.de/en/power-electronics-testing/

Sonplas will be showcasing at stand 1668 during the Testing Expo in Stuttgart, Germany from June 4th to 6th 2024.

Source/ Picture credits: Sonplas GmbH

About Sonplas GmbH:
Sonplas is a medium-sized mechanical engineering company headquartered in Straubing, Lower Bavaria. Since its establishment in 1993, the company has experienced steady growth. Sonplas now boasts a workforce of over 360 highly motivated employees.

In alignment with the motto “For your success,” Sonplas specialises in developing flexible and scalable specialist machines for processing, assembly, and testing. These can be complemented with external technologies as per the customer’s specifications. Over the years, the portfolio has consistently grown, and the specialist machine manufacturer now provides solutions for various sectors including electromobility, battery cell production, hydrogen technology, hydro-erosive machining, fuel injection, electronics, mechatronics, hydraulics, and aerospace technology. To date, the company has delivered over 1,000 specialised machines worldwide to renowned clients in the automotive, automotive supply, commercial vehicle industries, and aviation technology sector.

With its in-house research and development department, Sonplas consistently meets the latest technical demands in the market. With service partners located worldwide, the company offers on-site support to customers, providing expertise and spare parts directly when needed. What distinguishes Sonplas? Sonplas stands out for its profound expertise and thorough understanding of processes. Sonplas operates as both a system integrator and a general contractor. Sonplas delivers tailored solutions of the utmost quality to its customers.

Press contact:
Sonplas GmbH
Natalie Stroinski (Ms.)
Sachsenring 57
94315 Straubing
Germany
Phone: +49 9421 92 75 266
n.stroinski@sonplas.de
www.sonplas.de/en/

Media contact:
Werbeagentur Beck GmbH & Co. KG
Kerstin Schimmer (Ms.)
Alte Steige 17
73732 Esslingen
Germany
Phone: +49 711 93 78 93-30
schimmer@werbeagentur-beck.de
www.werbeagentur-beck.de

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