Skip to main content
EV Cold Plate Test and Inspection System
Automotive | Hipot Test Systems
TCA Technologies designed and built a turnkey automated EV cold plate test and inspection system that integrates feature verification, leak testing, dielectric strength (Hipot) testing, dimensional inspection, automated material handling, reject management, and MES traceability into a single production-ready solution.
The system was developed for high-volume EV manufacturing environments where every part must be identified, tracked, tested, inspected, and routed automatically. While the dielectric test process follows the same validated Hipot methodology used in previous equipment, this application expands the process into a fully automated multi-station platform with part tracking throughout the entire sequence.
Highlights
System Description
Cold plate assemblies are manually loaded into the system, where a barcode reader identifies each part and initiates electronic tracking. Part status, process results, and inspection data are exchanged with a central MES system to support full traceability and production reporting.
The first process step verifies the presence and positioning of required part features. The second step performs a leak test to confirm assembly integrity before the part advances to electrical validation.
At the third station, the system performs automated Hipot testing using controlled high-voltage application, connection verification, and pass/fail evaluation logic. Custom contact tooling and automated engagement help ensure repeatable test connections and reliable results.
The fourth and final station checks critical feature dimensions and angularity. Accepted parts are discharged on a servo indexing conveyor for manual removal, while rejected parts are automatically routed to localized reject conveyors at the station where the nonconformance is detected.
Key Outcomes
• Integrated inspection, leak test, Hipot test, and dimensional gauging in one automated system
• Full part traceability through barcode identification, in-process tracking, and MES data exchange
• Automated transfer using a dial table, servo indexing conveyors, and six-axis robots
• Localized reject handling at each station to protect downstream process flow
• Approximately 12–15-second part-to-part cycle time for high-volume production
System Capabilities
• Manual part loading with automated barcode identification
• Presence and position verification for required cold plate features
• Integrated leak testing prior to electrical testing
• Automated high-voltage Hipot testing with programmable voltage, dwell time, leakage thresholds, and connection verification
• Critical dimensional and angularity inspection at the final gauge station
• MES communication for part routing, result logging, and production traceability
Typical Cycle Time: Approximately 12-15 seconds part to part
Engineering and Design Execution
Mechanical & System Design
- Fully designed and engineered by TCA for automated EV cold plate inspection and test
- Multi-station architecture supporting feature verification, leak test, Hipot test, and dimensional gauging
- Automated transfer via dial table, servo indexing conveyors, and integrated robotic handling
- Precision fixturing and tooling to control part location throughout the process
- Localized reject conveyors positioned to remove nonconforming parts without interrupting accepted-part flow
Controls & Integration
- Safety PLC-based control architecture for coordinated station sequencing, transfer, fault handling, and safety system management
- Operator HMI for system status, part tracking, alarms, and test result visibility
- Barcode-driven part identification and station-to-station tracking
- MES integration for data exchange, pass/fail reporting, and production traceability
- Integrated safety controls for guarded automation, robotic stations, and high-voltage test areas
Test Station Design
- Feature presence and positioning inspection prior to functional testing
- Leak test station with automated handling and result capture
- Automated Hipot station using programmable voltage, dwell, leakage limits, and contact verification
- Final gauge station for critical dimensional and angularity checks
- Station-level reject logic to remove failed parts at the point of detection
System Components
Structural & Safety
- Guarded enclosure with Lexan panels and aluminum framing
- Safety-interlocked access doors with trap key entry for operator access
- Cell lighting for user visibility
Part Handling
- Manual load station with barcode read and part identification
- Dial table and servo indexing conveyors for controlled part transfer
- Six-axis robots positioned within the leak test, Hipot, and gauge stations
- Servo indexing discharge conveyor for accepted parts and manual removal
- Localized reject conveyors for nonconforming parts identified at any station
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: 24-32 weeks, application dependent on system complexity, automation scope and integration requirements
TCA Value Delivered
This project demonstrates TCA's ability to expand a proven Hipot test process into a fully automated EV Cold Plate Production system. By combining inspections, leak testing, high-voltage validation, dimensional gauging, robotics, servo conveyance, reject handling, and MES integration, TCA delivered a scalable solution that supports high-throughput manufacturing with strong process control and traceability.