DR - Single-station Controller Testing System

The single-station controller test system is a high-precision comprehensive detection device specifically designed for the controllers (ECUs) of electric scooters, balance bikes, and electric bicycles. By simulating the electrical load, temperature and humidity changes, and communication interference under real riding conditions, it comprehensively verifies the speed regulation accuracy, overload protection, EMC immunity, thermal management performance, and protocol compatibility of the controller. This system is suitable for R&D laboratories, small and medium batch production, and certification institutions, ensuring that products comply with international standards such as ISO 26262, EN 15194, and UL 2272, providing precise assurance for the reliability of the controller.

Application Scope

Single-station Controller Test System 

Core functional modules 

Full-parameter electrical performance testing

Dynamic load simulation:

1. Voltage range: 24V to 60V (expandable to 120V), current: 0 to 100A (accuracy ±0.1% FS), supporting constant current/constant voltage/constant power modes.

2. Simulate motor locked rotor, sudden load addition/removal, verify controller response time (≤10ms) and protection mechanisms (overcurrent, overtemperature, short circuit).

PWM speed control verification: Duty cycle 0 to 100% stepless adjustment, detect speed control linearity error (<±0.5%) and Hall signal synchronization.

Environmental and reliability testing

Temperature and humidity cycling: Temperature range -40°C to +120°C, humidity 10% to 95% RH, test high-temperature derating and low-temperature start-up performance.

Vibration testing: Random vibration (5 to 500Hz, acceleration 10g) and mechanical shock (50g, half-sine wave), verify structural reliability.

Intelligent communication and diagnosis

Protocol analysis: Support CAN, UART, I²C and other communication protocols, automatically verify speed commands, fault codes, temperature status and other data frames.

EMC immunity testing (optional):

1. Radiated immunity: 10V/m @ 80MHz to 6GHz (in accordance with ISO 11452-2).

2. Conducted immunity: 0.15MHz to 230MHz interference injection, verify anti-interference capability. 

Core technologies and configurations

Product advantages

Technical Highlights

High-precision power supply system: Programmable DC power supply + electronic load, dynamic response ≤ 1ms, ripple noise < 10mVrms.

Modular design:

1. Quick replacement of test fixtures (compatible with controllers of different pin definitions), compatible with brushless/brush motor drive solutions.

2. Optional battery simulator (supporting BMS communication), motor simulation module (back EMF simulation).

Safety protection: Overvoltage/overcurrent/short circuit protection, emergency stop, isolation transformer, compliant with CE/UL electrical safety standards.

Data traceability: Automatically generate PDF reports (including waveform diagrams, protocol logs, temperature rise curves), support integration with MES systems.

Equipment Advantages

High efficiency and accuracy: Single test cycle ≤ 3 minutes, data repeatability error < ±0.5%.

Flexible compatibility: Supports controllers for scooters, balance bikes, and electric bicycles, customizable test scripts and communication protocols.

Cost optimization:

1. Reduce repair rate by over 50% through early defect detection, lowering after-sales costs.

2. Energy feedback technology (optional) saves energy by ≥ 30%.

Standard compliance: Built-in ISO 26262 functional safety test process, one-click generation of ASPICE/ISO 21434 compliance reports. 

Application scenarios and industry value

R&D verification: Optimization of PID algorithms, MOSFET driver circuits, and heat dissipation design.

Production quality inspection: Full functional testing of controllers before leaving the factory (such as brake disconnection, Hall response, efficiency MAP).

Certification testing: Compulsory testing items for EMC and environmental adaptability in standards such as CE, FCC, and GB.

After-sales analysis: Defect reproduction and improvement for issues reported by users, such as controller overheating and speed regulation failure. 

After-sales Service

Warranty Policy: Most manufacturers offer a one-year full machine warranty, supporting remote fault diagnosis and operation training.

Customization Service: Customization based on requirements, including custom fixtures and software functions according to testing standards (such as JIS/CNS) to meet special needs.

After-sales Service: One-year full machine warranty, providing operation training and remote technical support.

Data Service: Optional cloud data platform for generating CNAS-compliant test reports remotely.

Technical Support: Free remote debugging, operation training, and annual equipment calibration services.

Spares Supply: Quick replacement service for consumable parts (fixtures, hydraulic seals). 

Ordering Process

Requirement Communication: Provide test standards and relevant parameters.

Plan Confirmation: The supplier provides 3D drawings and parameter lists.

Production and Delivery: 15-20 days for standard models, 30-45 days for non-standard customized models.

Acceptance and Training: Engineers install and debug on-site and provide on-site training.