Gen 3 Wall Connector Tester

As a power electronics engineer at Tesla, I played a pivotal role in architecting an intricate test system for the Gen 3 Wall Connector. My expertise in power electronics drove me to understand the electrical functionality of the wall connector intimately. Beyond curating specialized electronic tests, I spearheaded the mechanical design process — stretching my responsibilities from CAD conceptualization and meticulous drawing drafting to supplier management and procurement. I identified critical flaws before the China market release, and the resulting $140K automated pneumatic test system became a cornerstone of production validation.

I undertook a deep dive into SWC (Single-Wire CAN) debugging, ensuring that the Wall Connector's software interfaced perfectly with its electronics. I managed the mechanical design process singlehandedly — originating CAD designs, producing detailed drawings, and advancing to final prototype stages. I fostered collaborations with firmware teams, wireless experts, and hardware colleagues to create an integrated testing approach that encompassed all facets of the product.

The Resistance Test evaluates internal resistance to ensure optimal energy flow and reduced losses, connecting test points to a resistance meter and applying specific current levels across varied scenarios. The Hipot Test validates the connector's ability to handle potential over-voltage conditions without breakdown, applying elevated voltage levels to verify insulation strength. The Insulation Resistance test employs a dedicated insulation resistance tester to guarantee protection against unintentional current paths between the connector's components.

The Functional Test provides a comprehensive evaluation of assembly, firmware, and functional attributes — covering firmware updates, pilot circuit functionality, PLC circuit assessments, and more with clear parameters, procedures, and pass/fail criteria. The Zero Current Burn-In verifies sustained performance through real-time interactions with a Vehicle Simulator, providing consistent monitoring and management of voltage dynamics over extended periods.

The Leak Test ensures water ingress protection by maintaining specific pressures in a sealed environment and monitoring for potential leaks, guaranteeing long-term durability in various environmental conditions. Additional tests include UHF Transmission for energy metering accuracy, WiFi & NFC checks for wireless capabilities, and Energy Metering Calibration for precise energy transaction measurements — together forming a complete end-of-line validation suite.