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VALIDATION TESTING

Validation Process

Validation testing allows our complex designs, which bring together mechanical hardware, electrical hardware, and software, to be tested prior to being put into production . The validation process is an iterative process that helps refine the design and fix any unforeseen problems from integrating the design pieces together . FMEA and worst-case analysis give great indications of design suitability , but since there are always parasitic parameters and real-world interactions that are time-consuming and expensive to model , checking the design becomes easier through testing. During the initial design, a DFMEA is completed which gives indication of potential failure points to monitor during validation testing.

Testing standards have been developed to help designers and OEMs have confidence that the product will survive the environmental conditions to which they will be exposed . Pi Innovo uses typical automotive test standards when doing module validation. Customer standards and standards outside of the automotive industry (such as aviation ) have also been used for custom designed product.

EMC Tent

Pi Innovo develops high-quality ECUs , which survive harsh environments by using robust testing. Typical testing includes the following list, though these can change depending on the DV/PV, expected environment, and customer requirements for custom ECUs.

Test Name Specification
Immersion IEC 60529
Thermal Shock ISO 16750-4
Power Temperature Cycle ISO 16750-4
Vibration IEC 60068-2-64
Radiated Emissions CISPR-25
Conducted Emissions CISPR-25
Radiated Immunity ISO 11452-2
ESD ISO 10605
Short Circuit ISO 16750-2
Transient Immunity ISO 7637-2
Reverse Polarity ISO 16750-2
High Temperature ISO 16750-4
Low Temperature ISO 16750-4

The first samples, see the build stage moving into the integration test in the V-model, go through a full bench checkout to make sure all the designed features work as expected. Pre-DV tests are done in-house , which include a variety of electrical tests and temperature tests, such as high-temperature, low-temperature, short circuits, and doing a baseline EMC checks. Design improvements are implemented, based on findings in Pre-DV, and the next sample modules are made, which will be put through the entire design validation plan. Design improvements are made iteratively bringing the final product to the point of process validation, verifying that the ECU will be built correctly every time at the chosen production facility.