The Software Wavecontrol provides waveforms and controls the TOELLNER system components at the test station, which can be individually tailored to your requirements.

Using a DAQ-Card, any signal waveform can be provided with Arbitrary Power Supplies or 4-Quadrant Amplifiers with outputs from 160 W to 5200 W.

For fast interruptions, TOELLNER offers electronic switches with switching times below 500 ns.

The Software WaveControl provides extensive Waveform Libraries for Normative Tests, e. g.

High-Speed Signal Logging for ECU Development & Validation

Art Logics Smart Logger Series

ART Logics Smart Loggers are engineered for automotive ECU signal acquisition and bus analysis during development (DV), production validation (PV), and vehicle-level testing.

Automotive Relevant Technical Features

• Sampling rates up to multi-MHz range (100 kHz–10 MHz)
• Isolated inputs

Enables capture of:

• Speed Sensors output monitoring
• BMS cells inputs / Battery pack cells monitoring
• Injector drive signals
• PWM motor control waveforms (EPS, pumps, fans)
• DC-DC converter switching ripple
• Gate drive signals in power electronics

Synchronous multi-domain acquisition

• Analog voltages (±10 V / ±20 V / ±40 V)
• Current measurement (shunt-based or sensor-based)
• Frequency & PWM inputs

Automotive-Specific Features:

• Per-cell voltage simulation (0–7 V range)
• High precision (< millivolt-level accuracy)
• Current source >5A
• Independent channel isolation >1500V
• Active and Passive balancing function validation
• Rise time for all channels <1ms
• NTC temperature sensor simulation 0-8MOhm with 1 Ohm steps
• Fault injection capability (Short / Open circuit, Reverse voltage)

These systems are used to validate:

• Cell balancing algorithms
• State-of-charge (SoC) estimation
• State-of-health (SoH)
• Overcurrent & thermal protection
• HVIL (High Voltage Interlock Loop)

Because the channels are isolated, engineers can simulate:

• Module-level battery packs Cell drift scenarios
• Rapid transient conditions without physical batteries
• Significantly reduces risk during early BMS software validation

These test benches are used during:

• Design Verification (DV)
• Product Validation (PV)
• Lifetime Testing (LTT)
• Production End-of-Line

Key Automotive Use Cases:

• Insulation monitoring validation
• Pre-charge circuit testing
• Contactor control verification
• Pack fault diagnostics
• Compliance verification against OEM test specifications

Features:

• The Standard BMS Loadbox can drive BMS run as test cases.
• It simulate the specific signals for BMS.
• There are sufficient resources to monitor and measure specific BMS signals.
• There are CAN and LIN to communicate with BMS to diagnostic as specific test cases. It can support CAN FD as well.
• The Standard BMS Loadbox controlled by LAN.

Operating Modes:

• Constant Current (CC)
• Constant Voltage (CV)
• Constant Power (CP)
• Constant Resistance (CR)

These systems allow engineers to simulate:

• WLTP load cycles
• Dynamic driving current profiles
• Fast charge scenarios

BOLAB SOLUTIONS FOR AUTOMOTIVE TESTING

4-Quadrant Voltage amplifiers

Voltage/Current Stress Tests

• Voltage Source Tests – applying constant or swept DC voltage
• Current Source Tests – applying defined current profiles
• Voltage Sink / Absorption Tests – DUT injecting current into the amplifier

Dynamic / Transient Tests:

• Dynamic Waveform Tests – playback of recorded vehicle voltage/current profiles
• Transient Pulse Generation – short voltage/current spikes
• Ripple / AC Superimposition – adding AC noise to DC
• DC - 200 kHz bandwidth DC
• MHz (small signal -3 dB)
• Output voltage ±75 Vpk
• Rise / fall time 100 V/µs
• Power ranges from 500W to 12kW

• USB interface standard, LAN optional
• Analog control input 0 ... ±10 V for control of voltage and current
• Monitor outputs for measured voltage and current values (not all models)
• Modularly extensible via master-slave mode
• Parallel and Series Connections for two or more units

Regenerative / Bidirectional Tests

• Bidirectional Power Tests – amplifier can both source and sink power
• Custom Regenerative Tests – DUT returns power to supply

Typical low voltage tests that can be done for LV124 standard are

• E-05 Load Dump Test
• E-04 Jump Start Test
• E -15 Reverse Polarity Test
• E -10 Short Interruption Test
• E-11 Start Pulse Test
• E-06 Superimposed Alternating Voltage (Ripple) Test
• E-07 Slow Voltage Ramp Test
• E-02 Transient Overvoltage Test
• E-03 Transient Undervoltage Test
• E-09 Reset Behaviour Test

LV123 (High-Voltage Electrical Tests)

• E-101 – HV Overvoltage
• E-102 – HV Undervoltage
• E-103 – HV Voltage Ramp
• E-104 – HV Power Cycling
• E-105 – HV Reverse Polarity
• E-106 – HV Short Circuit
• E-107 – HV Interlock (HVIL) Test
• E-108 – HV Pre-charge / Discharge Test
• E-109 – HV Isolation Monitoring
• E-110 – HV Leakage Current Test

ISO 6469 / EV Safety Related Tests

• Insulation Resistance Test
• Dielectric Strength (Hi-Pot) Test
• Isolation Resistance Monitoring Test
• Ground Fault Simulation Test

Typical HV Functional Bench Tests

• HV Contactor Switching Test
• HV Load Simulation Test
• HV Power Supply Stability Test

Key Advantages of Bolab solutions for Automotive Components Testing

• Advanced Ripple Testing: Bolab’s unique series amplifier integration allows for precise ripple control across wide frequency ranges (10 Hz to over 300 kHz). This is critical for testing how HV batteries and inverters handle high-frequency disturbances from power electronics.
• Modular and Scalable Design: Systems can start small (e.g., 1 kW) and expand module-by-module up to 54 kW or more, allowing manufacturers to scale their testing capabilities alongside their budget and project needs.
• Real-World Simulation: Using AN-Series Artificial Networks, the systems replicate the actual impedance of a vehicle's power net. This enables "closer to real-world" testing of a component's robustness against internally generated noise like spikes and ripples.
• All-in-One Testing Capability: OLAB provides a comprehensive, all-in-one Test system solution for testing needs. With features like Arbitrary Function Generator, Voltage Amplifier, Current Amplifier, Voltage Measurement, Data Acquisition, Current Measurement, and Electronic Load (Current Sink), provide everything which is needed in a single system streamlining the verification process.
• Load Dump Capabilities: Unlike traditional coupling transformers, BOLAB’s 4-quadrant amplifiers can simulate sudden voltage spikes (load dumps), which are essential for meeting VW 80300 and LV 123 requirements.
• User-Friendly Software: The WaveMaster Software allows engineers to create complex waveforms graphically or via tabular input without needing specialized software development knowledge.
• Futureproofing: The hardware and software are designed to be easily upgradable, ensuring compatibility with evolving OEM standards and emerging global regulations for electric vehicles

Mantis Ergonomic Stereo Microscope

• Up to 20x magnification, eyepiece-less design
• Unique large, high quality optical stereo image for board-level inspection
• Ergonomic viewing head lets operators sit back in a natural posture during long ECU inspection sessions

LYNX EVO Stereo Zoom Microscope

• 6x–60x magnification for fine track and component inspection
• LED lighting with substage illumination for backlit PCB and connector inspection
• Multi-axis and Ergo stand options to suit ECU assembly and rework benches

SX Range Stereo Microscope

• 4x–200x magnification, Greenough design with excellent optical clarity
• Range of stand configurations for fixed inspection or line-side stations
• Cost-effective general-purpose option for incoming component and PCB checks

EVO CAM HALO

• 4K Ultra HD, 30fps digital inspection camera
• Auto lens ID and wide dynamic range for solder joint and component colour/contrast inspection
• Image capture with time-stamped reporting for traceable quality records

EVOCAM ICON

• Full HD camera with HDMI, USB3 and USB2 (stand-alone) connectivity, WiFi optional
• Suited to standalone or PC-linked inspection stations on the SMT line
• Image capture and time stamping for solder joint quality reporting

OPTA

• Eyepiece-less viewer with perfect depth perception for crimp and terminal inspection
• 4x and 6x magnifications suited to fast, repetitive harness-line checks

LYNX EVO

• Substage illumination for backlit inspection of connector cavities and terminal seating
• Ergo stand configurations for harness and connector assembly stations

ProteQ VISO – Digital 3D Inspection Microscope

• X0.45 to X2.0 magnification for larger automotive components and assemblies
• 18° display tilt and 360° oblique and direct viewer for weld seam and surface defect inspection
• Non-contact 3D viewing for dimensional checks on machined and cast parts

DRV-Z1

• 6x–186x magnification with true 3D view, capture and share
• 3D imaging without special glasses, ideal for connector pin alignment and small-part QC

DRV STEREO CAM

• 8.4x–700x magnification range covering fine BGA/SMD detail up to broader assembly views
• 3D view, capture and share for weld seam, gear tooth and sensor housing inspection

Wave LED / Circus LED / KFM LED / LFM LED G2

• 1.75x–4.75x magnification with dimmable LED illumination
• Edge clamp, K-arm and steel-arm mounting options to fit harness and assembly benches
• Full-circle, flicker-free illumination for virtually shadow-free crimp and terminal viewing

BenchKam

• Exclusive to Vision Engineering — easy image capture directly from the bench magnifier
• Maintains the 3D view available through the magnifier, useful for rework documentation and traceability

Nano Stations

• Designed for soldering and rework of the smallest SMD components (down to 01005/0201/0402)
• Extremely light, ergonomic tools for high-precision work on ECU and sensor PCBs
• Fast heat-up and tip recovery to keep production throughput high

Compact & B-IRON Stations

• General-purpose soldering stations for automotive PCB assembly and bench rework
• B-IRON offers Bluetooth connectivity and cordless operation for flexible line-side use
• Sleep & Hibernation modes reduce oxidation and extend tip life during pauses on the line

RMSD / RMSE Complete Rework Systems

• Combines a 2-tool DDE control unit, soldering iron, hot air station and electric vacuum desoldering module in one system
• Compatible with up to 10–13 different JBC tools for a fully personalised automotive rework bench
• Up to 85% vacuum for precise, efficient solder removal on multi-layer automotive PCBs

Hot Air Stations

• Fast, even heating with precise temperature and airflow control for BGA/QFP rework
• Contactless desoldering minimises thermal risk to neighbouring automotive-grade components

Heavy Duty (HD) Stations

• The most powerful JBC soldering stations, built for applications requiring large amounts of heat
• JBC Exclusive Heating System with Sleep & Hibernation Modes to extend tip life on high-duty-cycle lines
• Suited to busbar, connector terminal and heavy-gauge harness soldering in EV and powertrain assembly

DR560 Desoldering Iron / MSE Electric Desoldering Module

• Used for desoldering through-hole components and clearing excess solder after rework
• Powerful vacuum suction for clean, damage-free hole clearing on multi-layer automotive PCBs

JBC Automation & Robots

• Automated soldering integration for consistent, repeatable joint quality on high-volume lines
• Reduces cycle time and operator-dependent variation on repetitive automotive assembly tasks
• Pairs with JBC's Auto-Feeder for continuous wire-solder feed on automated stations

Auto-Feeder

Automatic-Feed Soldering Iron

• Automatic solder wire feed for consistent solder amount across repetitive automotive joints
• Improves line speed and reduces operator fatigue on high-volume soldering stations

Preheaters & Rework Benches

PHBE Preheater

• Avoids thermal shock on multilayer automotive PCBs during rework
• Combined preheater and PCB support solution for medium/large PCBAs and panels

Fume Extractors

FAE1 KIT2

Fume Extractor Kit for 2 Workbenches

• Captures solder fumes at source on automotive assembly and rework benches
• Protects operator health and supports ESD/EC-compliant, safe working environments

Tools & Stands / Cartridges & Tips

• Wide range of tip shapes suited to virtually any automotive soldering, desoldering or rework application
• Intelligent stands auto cut-off power when tools are placed down, extending tip life on busy production lines