Integrating High-Voltage Automated Test Benches into Automotive Production Lines

Vehicle electrification is increasing the complexity of automotive thermal-management and electrical-heating systems. Manufacturers must validate electrical safety, insulation and product robustness directly within high-volume production, under strict cycle times. A leading tier-1 automotive supplier specialising in vehicle thermal management partnered with T&S to develop and integrate a dedicated automated testing platform for electrical heating systems - a complete industrial test bench performing high-voltage HIPOT and stress tests directly on the production line.

Client context

The client was preparing the industrialisation of electrical heating components for automotive production programs and needed a system to validate electrical insulation, dielectric strength and product resistance during manufacturing, supporting OEM production-startup constraints while integrating seamlessly into an existing line, as part of a broader effort to reinforce product quality, electrical safety and production reliability for high-power electrical systems.

Business challenges

• Perform automated HIPOT and stress tests within a 28-second production cycle time
• Manage electrical conditions up to 1500 volts and 90 kW while ensuring operator safety and measurement reliability
• Integrate the testing solution into the manufacturing environment without disrupting production flow or OEM startup planning
• Coordinate mechanics, electrical systems, automation, fabrication and commissioning within a compressed timeline

The T&S solution

T&S delivered an end-to-end engineering approach covering design, realisation, installation and commissioning of the automated testing system, managing mechanical engineering, electrical integration, automation development, supplier management, fabrication and wiring. The platform was structured around four industrial stations - loading/unloading, dielectric testing, stress testing and cooling-station integration. To meet industrial cadence, T&S implemented Siemens PLC automation synchronised with the production line, respecting the 28-second cycle time (under 5 s per piece), with high-voltage testing for insulation and leakage-current verification. T&S also supported commissioning, debugging, operator training and production startup on the customer site.

Technologies & expertise

• Siemens PLC
• TIA Portal
• SEE Electrical
• SolidWorks
• HIPOT testing systems
• up to 1500 V / 90 kW
• 28 s cycle time

Results & business value

• A fully integrated high-voltage testing platform deployed directly within the automotive production line
• Reliable dielectric and stress-testing within a constrained 28-second cycle compatible with OEM requirements
• Improved testing repeatability, industrial robustness and operational reliability for high-power electrical heating components
• Reinforced electrical-safety validation while maintaining production performance objectives

Conclusion

The project highlights T&S's expertise in industrial automation, electrical-testing systems and production-line integration, illustrating the growing importance of automated validation in the industrialisation of electrified automotive components.