Testing system for soldering stations

Modern soldering stations are complex devices with a lot of electronics. At the end of production, the quality must be ensured by a safety and function test.

Industry: electrical industry


It was aimed for a largely automatic test for safety and function according to globally applicable standards (IEC, EN, UL, VDE etc.) The workplace should be optimized due to the high testing volumes. Moreover, the test durations and handling times must be shortened, while maintaining or even increasing the testing depth. The systems must feature a free choice of languages and a flexible power supply as they are proposed to be used throughout the world.


The PC-controlled testing system gets a tandem DUT enclosure. Simultaneous mounting and testing results in optimum load for human and machine. Manual mounting of the testing system had to be chosen as the production lines were not designed for a fully automated process. The tandem concept was the ideal solution for integration into existing production processes.

The turnkey testing systems consist of testing equipment, tandem DUT enclosure, PC hardware with software and DUT support / adapter. The customer was able to change over his production in a short time after the completion of the systems. The new system has adapted to the existing production.

Following the safety tests, which could be arbitrarily designed like all other tests, the testing system performs the required function tests of soldering stations. A fully electronic, programmable source supplies the DUT with all voltages and frequencies known worldwide. Load and thermal resistances are simulated by the testing system.

An arbitrary number of test programs can be stored in the testing system PC. This allows the customer to independently write new test programs while developing products. However, for products with identical data, it is also possible to use the same test program, which is then allocated to the respective DUT over the product list. The test results are stored automatically in XML or Access format on an arbitrary place on the network.

A separate test dummy is used to check the functionality of the testing system fully automatically. During the daily start of the testing system, the testing personnel is asked to connect this dummy and start the corresponding program. The testing system does not allow further testing without a passed dummy test.

    • Turnkey solution including DUT support, adaptation and workplace design
    • Simple, intuitive operation for semiskilled personnel
    • The DUT needs to be connected only once, then the whole test process occurs automatically
    • In network operation, all test data is automatically saved at the specified location / database
    • Long service life and service-friendly design
    • All values and settings can be made using software
    • Automatic dummy test
    • Workplace safety standard
    • Automatic test program selection
    • Simple and quick retooling for different versions
    • Optimized workplace with tandem DUT enclosure
    • Optimized processes for human and machine by simultaneous testing and mounting
    • Fully electronic, programmable source for function test
    • Power source 0 – 300 V / 5 kW
    • Hipot test ≤ 5,000 V AC / 6,000 V DC
    • Ground bond test ≤ 30 A / max. 600 mΩ
    • Insulation test ≤ 6,000 V DC
    • Function test 0 – 5,000 W
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