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EV Cold Plate Hipot Test System
Automotive | Assembly
TCA Technologies designed and built a turnkey automated system to perform dielectric strength (hipot) testing on EV cold plate assemblies. The system verifies electrical isolation integrity between customer specific regions and conductive elements, ensuring product quality prior to final assembly.
The project encompassed full process development, equipment concepting, detailed design, in-house manufacturing, controls integration, and system validation. Both manually loaded and fully automated configurations have been successfully deployed, with this case study highlighting a high-throughput, manually loaded/unloaded system.
Highlights
System Description
Cold plate assemblies are manually loaded into precision fixtures at a guarded load station equipped with safety light curtains. Each part is identified via barcode scanning to enable full traceability.
Parts are automatically transferred to the hipot test station, where high-voltage dielectric testing is conducted under tightly controlled conditions. Custom-engineered electrical contact tooling ensures consistent connections and safe application of high voltage.
To maintain test integrity, the system performs continuity and connection verification on every cycle, confirming both high-voltage electrode contact and return paths. This prevents false-pass conditions and ensures reliable test results.
Following testing, results are logged to the customer's data collection or MES system, and parts are presented for manual unload and downstream processing.
Key Outcomes
- Reliable verification of insulation integrity for EV cold plate assemblies
- High repeatability through precision fixturing and controlled test conditions
- Integrated traceability via barcode scanning and MES communication
- Optimized production cycle times for high-volume manufacturing envrironments
System Capabilities
- Manual load/unload with automated part handling
- High-voltage hipot testing with programmable voltage, dwell time, and leakage thresholds
- Continuous validation of electrical connections to eliminate false passes
- Pass/fail determination based on defined voltage and current criteria
- Data collection and traceability through MES integration
Typical Cycle Time: 10-30 seconds (application-dependent)
Engineering and Design Execution
Mechanical & System Design
- Fully designed and engineered by TCA
- 3D modelling in SolidWorks
- In-house manufacturing using CAD/CAM systems
- Welded, powder-coated structural steel frame
- Compact footprint (~4 ft x 6 ft)
Controls & Integration
- Allen-Bradley CompactLogix PLC platform
- PanelView Plus HMI for operator interface and visualization
- Integrated safety controls and light curtain protection
- Custom sequencing, validation logic, and cycle optimization
- MES system integration for traceability
Test Station Design
- Programmable hipot tester (voltage, dwell, leakage limits)
- Custom electrical contact tooling for reliable engagement
- Automated electrode continuity verification
- Robust pass/fail evaluation logic and verification cycles
System Components
Structural & Safety
- Guarded enclosure with Lexan panels and aluminum framing
- Safety-interlocked light curtains for operator access
- Cell lighting for user visibility
Part Handling
- Manual load fixture with precision locating and clamping
- Automated transfer and clamping system (pneumatic or servo, application dependent)
Validation, Delivery & Support
- Full system validation at production cycle rates prior to shipment
- Complete installation and commissioning support
- Operator training (on-site or at TCA facility)
- Comprehensive documentation package, including:
- Operation Manual
- SolidWorks assembly drawings
- Electrical schematics
- PLC and HMI code
Warranty: 2 years or up to 6000 operating hours
Typical Lead Time: 16-20 weeks (depending on system complexity)
TCA Value Delivered
This project demonstrates TCA's ability to deliver fully integrated test systems - from concept through commissioning - that combined robust mechanical design, advanced controls, and reliable high-voltage testing in a production ready solution.