Load boxes support EMC testing of zone controllers

Zone controllers are becoming increasingly important in modern vehicle architectures. By consolidating the control of numerous sensors and actuators in each area of the vehicle, they significantly reduce wiring complexity – but also create new demands on test systems during development. Compared to traditional ECUs, zone controllers feature a much higher number of pins and increased control complexity, making reliable and realistic testing essential.

A flexible test solution for demanding requirements

Together with Valeo Schalter und Sensoren GmbH, SMART TESTSOLUTIONS has developed a modular load box tailored specifically to the needs of zone controller testing. A single box can simulate up to 150 loads per setup – covering the full range of sensors and actuators in a vehicle zone.

A key development goal was full compliance with EMC testing requirements. Our solution is housed in a shielded industrial-grade enclosure that ensures low emissions and is suitable for use in sensitive EMC test environments. For direct voltage measurement at the loads, we rely on our proven Multi-Channel Modules (MCM), which can be easily controlled via CAN.

From the EMC chamber to the development lab

In mid-2024, we delivered the final prototype to Valeo. Since then, several versions of the load box have been in operation – not only in the EMC chamber, but also in day-to-day development workflows. The project demonstrates how SMART TESTSOLUTIONS delivers robust, scalable test systems through customized hardware and close collaboration – especially where standard solutions fall short.

The trade magazine Hanser Automotive has published a feature on the project in its current issue, including technical details and deeper insights: Read the full article at hanser-automotive.de

Or download our compact project summary on the SMART TESTSOLUTIONS EMC load box directly here: Download the PDF

If you have questions about the project, feel free to contact my colleague Stefan Fuchs – you can book a meeting with him directly here: Book a meeting online