High-Current LXI Switching Systems for Automated Power Testing

Pickering Interfaces is releasing the 60-191 LXI high-current and sense single-pole single-throw (SPST) switching family, designed to manage high-power signal routing up to 80 A and 300 V. This hardware simplifies the distribution, sequencing, and management of multiple high-current power supplies for technical applications spanning electric vehicle battery testing, solar inverter verification, and advanced aerospace development.

Integration into Automated Test Systems
Integrating high-current switching within automated test systems historically required engineers to build custom assemblies using discrete contactors and digital output modules. The 60-191 family replaces these custom builds with a standardized, maintainable 4U enclosure. This hardware architecture supports functional testing across the digital supply chain, specifically targeting fuel-cell research, hydrogen-electrolysis, and high-drain automotive electronics where reliable, automated power distribution is critical.

Relay Configuration and Control Mechanics
The switching units are available in four standard configurations, housing up to twenty 40 A and four 80 A hermetically sealed SPST normally open (NO) contactors. These are paired with a corresponding number of 1 A SPST relays dedicated specifically to sense lines. Hardware engineers can programmatically connect and disconnect the positive and negative outputs of a power supply unit alongside their respective high and low sense lines via front-panel screw-terminal connections.

The system allows for independent control of every relay, or the grouped operation of two high-current and two low-current relays using a single command. This grouping mechanism streamlines the switching of standard four-wire power supply connections, reducing the complexity of control code required to manage multi-channel power injection.

Sequence Storage and Network Connectivity
To reduce host transactions and minimize system latency, each unit features an onboard sequencing service capable of storing up to 5,000 predefined switching sequences. These sequences are executed either through software commands or configurable hardware triggers directly from the chassis.

The hardware operates via an LXI 1.5-compliant 1000Base-T Ethernet interface, utilizing an application programming interface (API) or a built-in soft front panel. System integration is supported by Interchangeable Virtual Instrument (IVI) and direct I/O drivers compatible with Windows, Linux, LabVIEW, Python, C/C++, C#, MATLAB, and Simulink. Additional diagnostic features include front-panel light-emitting diodes (LEDs) for status indication and native relay cycle counting to support predictive maintenance schedules and balance physical wear across available switching paths.

Additional Context
This section details technical specifications and competitive benchmarking not included in the original news release.

In the automated test equipment (ATE) market, LAN eXtensions for Instrumentation (LXI) switching systems are predominantly manufactured by companies such as Keysight Technologies and VTI Instruments (AMETEK). A primary objective benchmark for these systems is the maximum internal current carrying capacity and the integration of native sense lines for four-wire measurements.

Standard high-density LXI mainframes, such as the Keysight 34980A or VTI EX1200 series, typically support internal multiplexer and matrix modules rated between 1 A and 16 A. To switch continuous currents approaching 80 A, test engineers generally must route low-voltage control signals from the LXI chassis to external, third-party electromechanical contactors mounted on separate relay panels. By integrating 80 A and 40 A hermetically sealed contactors directly into a single LXI 1.5-compliant 4U chassis alongside 1 A sense relays, the 60-191 architecture eliminates the need for distributed external contactor wiring, thereby reducing the overall volumetric footprint of the test rack and lowering potential points of failure in the wiring loom.

Edited by Aishwarya Mambet, Induportals Editor, with AI assistance.

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