Suzhou Weichuang Electric reminds you:
Of the myriad products available, reliability is paramount.
Careless testing will bring tears to your customer's eyes!
---R&D Center - Pilot Production Department
Hello everyone, I am Pinpin. As a new generation product of Weichuang Electric, I shoulder the mission of revitalizing the family. After undergoing numerous tests by R&D and pilot engineers, I have completed this major "baptism" through rigorous refinement. I combine exquisite appearance, convenient operation, and wide applicability, and have perfect performance with high precision, high response, and high stability. Below, I will tell you about my growth journey.
The essential path to growth: Single-board hardware circuit testing → Complete machine type testing → EMC environment testing → Software testing → Reliability testing (shown in image format)
Hardware Testing
Pinpin: Hello everyone, I'm Pinpin. It's nice to meet you all. My husband says that before we can officially meet, we'll need to go through a long process of getting ready.
From its inception, I was sent to a single-board testing lab. Pilot engineers rigorously tested my various components and the circuits they formed, using a variety of precision electronic instruments for signal simulation, acquisition, debugging, and testing, such as the 500MHz oscilloscope MDO 3054, the function generator DG1062Z, and the electronic load tester IT8211, etc. Let's take a closer look at the specific process!
First, a comprehensive physical examination is required.
We conduct electrical clearance inspections and withstand voltage tests, in accordance with national standards or even exceeding those standards, to ensure the reliability of our products and users.
Frequently: Thanks to my standard "growth" and ample "endurance", otherwise I might not have even passed the first test. It seems that this baptism will be quite challenging. The next test will examine my internal "nervous system", my immune system, and whether I am prone to "fever", etc.
The nervous system test mainly involves testing the hardware circuitry of the main board, examining aspects such as the accuracy of the logic, the adequacy of the response time, and the load-bearing capacity.
Immunity – Perform a temperature rise test
Temperature rise test step one: thermal simulation using software during design.
Temperature rise test stage two: actual load test, and infrared thermal imaging scanning to assist in the analysis of heat generation.
Temperature rise test stage three: more refined stickiness test
Pinpin: This test was really comprehensive. Luckily, I have a quick and accurate reaction time and a strong immune system, so I'm less likely to get a fever. Otherwise, I might have failed.
Narrator: What follows will be the most important part of this rigorous testing process, and it will be the key to whether "Finpin" can successfully pass the rigorous testing process.
First, various protection functions such as overvoltage, overcurrent, input and output phase loss, overload, and overheating are tested. Second, the reliability of protection against extreme field conditions such as short circuit to ground and phase-to-phase short circuit is verified.
Short circuit test
Vibration test
Dustproof test
High and low temperature tests, start-up test at -40℃, and high temperature test at 50℃.
High temperature aging
Salt spray test
drop test
EMC testing (lightning surge immunity and burst pulse immunity testing)
EMC test (electrostatic discharge immunity test)
Pinpin: After undergoing a rigorous, "devilish" test, I realized how much effort and dedication from countless people working day and night was needed for my creation. This is both a sign of respect for me and a responsibility to the company and customer service. It has made Pinpin more mature and composed, able to remain calm and collected even under the most demanding conditions. But this is still not enough to meet my family's standards. They still need to assess and refine my "moral character." What kind of test will that be?
Software Testing Section
Frequently: Through software testing, my competitiveness has been further enhanced, with more complete functions and more precise performance. Whether it is the direct logic application from the customer's external terminals or the performance debugging of internal advanced functions, they will conduct repeated experiments one by one, so that I can have better control even when I am in a critical limit state.
High-speed operation simulates load changes for the tractor unit; a power analyzer monitors harmonics and power losses in real time; and a torque-speed measuring instrument collects the actual current motor speed and torque in real time.
Because the overmodulation function's performance was not ideal in some details, they simulated application scenarios and conducted multiple rounds of repeated optimization tests based on waveforms to trace the root cause of the problem until it was completely resolved.
Precise signal logic combination control is the best presentation of perfect hardware and software cooperation: from signal identification, acquisition, processing, and calculation to accurate speed tracking across low, medium, and high frequency bands.
Furthermore, the pilot engineers also strive for excellence in their "defense system." They simulated various field application conditions, taking into account environmental factors, load conditions, and diverse combinations of usage operations, to create a robust armor to cope with external conditions. The system has more than 160 protection mechanisms, such as overvoltage, overcurrent, overload, overtemperature, short circuit, phase loss protection, and anti-interference. Some of these protection functions have a response speed of up to the microsecond level.
Overcurrent protection response 6µs, overvoltage suppression effect
To adapt to the trend of intelligent development, communication bus equipment is naturally indispensable: RS485 communication, CANopen, PROFIBUS-DP, M2, EtherCAT bus, etc. Engineers will conduct logical analysis tests on each frame of data during the bus transmission process, and the success rate of multi-unit communication, the maximum transmission distance, and anti-interference tests are all key focuses.
CAN bus parsing test
Multi-unit communication test
Software testing has further enhanced my competitiveness, making my functions more complete, my performance more accurate and powerful, and my protection more comprehensive and reliable. Ultimately, it has created the different me I am today.
"The road ahead is long and arduous, but I will persevere in my pursuit." We firmly believe that we will become a first-class enterprise in the field of electrical drives and industrial control.
