Client Description​

​Our Cambridge-based client specialises in the design and manufacture of micro solar inverter equipment with integrated Zigbee communication capabilities for monitoring via a gateway.

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Test Environment​​

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Simulator Development

• Built a custom simulator in LabVIEW, interfacing with Python scripts to facilitate comprehensive verification and validation (V&V) activities.​

• Simulated large-scale inverter installations to assess system capacity and scalability.

Manufacturing Test System​​

• Developed and maintained a robust test system for a contract manufacturer in Poland.

• Expanded the test system to support an additional manufacturing site in the United States.

• Integrated Python scripts across all test systems to streamline automation and ensure consistency.

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Inverter Testing Procedures

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Functional Testing​​

• Performed functional tests on inverters using Solar Power Simulator Power Supplies.

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Key Test Scenarios

• Islanding Detection: Verified that the inverter output is automatically shut off when external mains power is disconnected to ensure compliance with safety standards.

• Output Frequency Limits: Tested the upper and lower frequency limits of the inverter output to ensure proper operational boundaries.

• Voltage Limits: Conducted tests to confirm the inverter operates within predefined voltage thresholds.

• Power Factor Tests: Assessed the inverter’s ability to maintain optimal power factor under varying load conditions.

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Advanced Performance Testing:​

• Maximum Power Point Tracking (MPPT): Evaluated the inverter’s efficiency in maximizing power extraction under varying solar input conditions.

Regulatory Compliance Testing:​

• Conducted comprehensive testing to ensure compliance with BS EN 50438:2007 standards, focusing on grid-interfacing requirements and safety protocols.

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Achievements

• Delivered a scalable test environment capable of handling diverse manufacturing and testing requirements.

• Ensured compliance with international standards and enhanced product reliability through rigorous testing.

• Supported seamless integration and automation across multiple manufacturing sites, improving overall productivity and quality assurance.

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