Custom Load Box Test Solutions
For automotive electronic controller R&D, validation and test bench applications, Takemind turns temporary wiring, scattered loads and field issue reproduction into structured, reusable and engineering-ready load box solutions.
Validation Scenarios
Electrical, EMC, durability and HIL testing
DUT Coverage
BMS, ZCU, TMS, chassis controllers and BLDC controllers
Delivery Formats
Portable cases, desktop boxes and 19-inch rack systems
From Requirements to Delivery
Pinout definition, load selection, panel layout, harness labels and test documentation
How We Support Your Test Project？
Takemind provides customized load boxes for automotive ECU testing, integrating load simulation, fault injection, interface adaptation and test system connection.
Load Simulation
Configure real loads, equivalent loads or programmable loads according to controller output characteristics, covering lamps, motors, valves, relay coils, power resistors and other load types.
Fault Injection
Integrate open circuit, short to battery, short to ground, channel-to-channel short circuit and intermittent contact faults into controllable switches or relay matrices for repeatable verification.
Interface Adaptation
Convert ECU connectors, banana jacks, D-Sub, BNC, aviation connectors and test bench interfaces into a clear front panel to reduce wiring mistakes and maintenance cost.
System Integration
Work with relay cards, data acquisition cards, power supplies, electronic loads, CAN/LIN/Ethernet devices and host software to support HIL, durability and production test systems.
Load Box Types for Automotive Standard Validation
Takemind modularizes key controller test functions and configures them into load boxes for automotive standard validation, laboratory testing and on-site troubleshooting.
Electrical Test Load Box
Used for power drop, startup waveform, overvoltage, undervoltage, reverse polarity, short circuit, output load and channel monitoring tests, allowing ECUs to operate under vehicle-like electrical boundary conditions.
ISO 16750-2
LV124 / LV148
VW 80000
GMW 3172
EMC Test Load Box
Provides stable loads, shielded harnesses, remote connections, grounding and repeatable layouts for chamber tests, BCI tests, transient pulse tests and conducted or radiated emission tests.
CISPR 25
ISO 11452
ISO 7637
UN ECE R10
Durability Test Load Box
Designed for long-term cycling, actuation life tests, temperature rise monitoring and functional retention tests after mechanical or thermal stress, suitable for durability benches and reliability validation.
ISO 16750-3
ISO 16750-4
LV124 M/K 类
OEM DVP&R
HIL Load Box
Serves as the engineering interface between the DUT and the real-time simulation system, integrating real or equivalent loads, I/O, relay matrices and fault injection to build an automated closed-loop test environment.
ISO 26262 validation
ASPICE test evidence
OEM HIL specifications
Portable Load Box
Used for laboratory debugging, sample validation, field issue reproduction and production spot checks by integrating common loads, interfaces, measurement points and protection design into a portable enclosure.
Quick debugging
Sample validation
Field diagnostics
Production spot checks
Fault Injection Load Box
Provides controllable reproduction of open circuit, short to battery, short to ground, channel-to-channel short circuit, intermittent contact and abnormal load conditions for robustness and safety mechanism validation.
LV124
ISO 16750
ISO 26262
Fault reproduction
Configurable Capabilities
To help evaluate the solution and quotation more efficiently, we recommend preparing the following information first. If the information is incomplete, Takemind can clarify it step by step during technical communication.
1
Requirement Clarification
Define the DUT type, channel count, connector interface, load power, test standards and existing test bench boundaries.
2
Solution Design
Provide panel layout, load topology, protection strategy, fault injection matrix and harness connection design.
3
Assembly and Verification
Complete enclosure processing, harness labeling, channel continuity check, insulation withstand test and functional verification.
4
Documentation Delivery
Provide pinout tables, wiring lists, user instructions, maintenance suggestions and necessary test records.
Requirement Table May Include
- DUT name, connector model and pinout definition
- Load type, resistance, power rating and accuracy
- Open circuit, short circuit, short to battery and short to ground requirements
- Banana jack, BNC, D-Sub and aviation connector layout
- Cooling, fan, temperature control and status indicator requirements
- Power level, maximum current and protection method
- Channel count, grouping method and switching logic
- CAN、LIN、FlexRay、Ethernet interfaces
- Host software, relay card and data acquisition card integration
- Harness length, shielding, labels and color rules
Typical Delivery Case Directions
The following case directions cover common automotive controller testing projects
BMS Load Box
For battery management controllers, integrating sampling channels, wake-up signals, relay control, insulation monitoring interfaces and fault injection to support BMC / BMU functional validation.
48V ZCU Load Box
For zone control units, supporting 48V power supply, high-current circuits, multi-channel actuator loads, CAN / LIN / Ethernet communication and high-pin-count harness adaptation.
TMS Load Box
For thermal management controllers, simulating water pumps, fans, valves, heaters, temperature sensors and PWM outputs for functional testing, durability testing and fault reproduction.
Chassis Controller Load Box
For braking, steering and suspension controllers, providing valve, motor, sensor, power supply and fault injection interfaces to support HIL and test bench validation.
Airbag Controller Load Box
For airbag control units, configured with equivalent ignition circuit loads, crash sensor interfaces, power disturbance and safety isolation design for safety strategy validation.
BLDC Load Simulator
For brushless DC motor controllers, simulating three-phase motor loads, Hall or position feedback, PWM drive signals and abnormal operating conditions for motor control strategy and protection validation.
Contact Us
上海夺智智能科技有限公司
SHANGHAI TAKEMIND INTELLIGENT TECHNOLOGY CO., LTD
上海市嘉定区育绿路288号 5号楼
Building 5, No.288, Yulu Road, Jiading District, Shanghai
info@takemind.com
+86(0)21-5997-0838