Application and Technical Research of LISUN LED Driver Online Test Solution in Production Line Finished Product Testing

Abstract
In the large-scale production of the LED lighting industry, the LED driver, as a core power supply component, its long-term operation stability directly determines the service life and safety performance of LED lamps. If the finished product testing link in the production line lacks standardized and efficient testing equipment, unqualified products are likely to flow into the market, increasing after-sales costs and brand risks. This paper takes the LISUN LEDRACK-100W192P LED Driver Online Test Solution as the research object, and combines its technical characteristics that comply with standards such as IEC 62384 and GB/T 24825-2009 to systematically analyze the core value of this equipment in finished product testing on the production line. By interpreting the equipment’s system configuration, technical parameters, operation process and after-sales support, this paper expounds its advantages of “simple operation, efficiency improvement and standard compliance”, providing practical references and technical support for LED driver manufacturers to optimize quality control processes and reduce testing costs.

1. Introduction
LED lighting products have been widely used in home, commercial, industrial and other fields due to their advantages of energy saving, long service life and environmental protection. As the “heart” of LED lamps, the LED driver undertakes the key function of converting commercial power into a stable DC/AC power supply. Its performance stability directly affects the lighting effect and service life of the lamp. If the driver has problems such as capacitor aging, abnormal chip heating and output voltage fluctuation, it may cause the lamp to flicker, brightness attenuation, and even lead to safety accidents such as short circuits and burnout.

To ensure the outgoing quality of LED drivers, the production line needs to simulate the long-term operating environment of the product through “aging testing” to screen out early failed products. Traditional aging testing mostly uses simple tooling, which has problems such as inconvenient load adjustment, manual data recording and low testing efficiency, making it difficult to meet the needs of large-scale production. The LEDRACK-100W192P LED Driver Online Test Solution developed by LISUN Group integrates automatic control, data acquisition and standardized load, and strictly follows international and national standards, becoming a dedicated equipment for finished product testing of LED driver production lines. This paper will comprehensively analyze the technical advantages and practical value of this LED Driver Online Test Solution from the aspects of equipment technical principles, system configuration and application scenarios.

2. Working Principle and Core Functions of the LED Driver Online Test Solution
2.1 Working Principle
The core principle of the LED Driver Online Test Solution is to “simulate the long-term operating environment and accelerate the failure process”. By providing stable load and temperature control conditions for the LED driver, the driver is operated continuously for a period of time (usually 4-24 hours) under the set voltage, current and temperature, simulating its long-term working state in actual use. During this process, the equipment continuously monitors the output parameters (voltage, current, power) and ambient temperature of the driver. If the parameters exceed the standard range or abnormal fluctuations occur, the driver is judged as an “aging-failed product” and needs to be rejected and the cause analyzed.
The working process of the LISUN LEDRACK-100W192P LED Driver Online Test Solution is divided into three stages:
• Parameter Setting Stage: Preset test parameters through the aging control system (computer + dedicated software), including aging time (e.g., 8 hours), temperature range (e.g., RT+10℃~60℃), load mode (e.g., CC constant current mode), voltage/current thresholds, etc.;
• Aging Operation Stage: Connect the LED driver to be tested to the test interface of the online test solution. After starting the equipment, the temperature control device adjusts the ambient temperature to the set value, the LED load module simulates the actual load demand of the LED lamp, the online test solution provides a stable input power supply for the driver, and at the same time continuously collects output voltage, current, power and temperature data;
• Data Judgment Stage: After the test is completed, the software automatically conducts statistical analysis on all data, generates an aging test report, marks unqualified products with excessive parameters, and supports the export and traceability of test data.

2.2 Core Functions
The core functions of the LISUN LEDRACK-100W192P LED Driver Online Test Solution focus on “automatic testing, standardized compliance and efficient production”, which are specifically reflected in the following four points:
• Multi-Mode Load Adaptation: It supports five load modes: CC (constant current), CV (constant voltage), CR (constant resistance), CP (constant power) and LED. It can simulate the actual working load of different types of LED drivers (such as constant current drivers, constant voltage drivers and multi-channel drivers), and is suitable for LED drivers with power ≤100W, meeting the diverse testing needs of the production line;
• Real-Time Monitoring of All Parameters: The software interface displays real-time parameters such as voltage, current, power and temperature of each test station. The data sampling frequency can reach 1 time per second, avoiding manual recording errors. At the same time, it supports abnormal parameter alarms (e.g., automatic sound and light reminders when the current exceeds the threshold), ensuring timely detection of unqualified products;
• Standardized Temperature Control: It has a built-in K-type thermocouple temperature collection and temperature control device. The temperature adjustment range is RT+10℃~60℃, and the temperature control accuracy is ±2℃. It can simulate the operating state of the LED driver in a high-temperature environment in summer, and screen out failed products caused by poor temperature adaptability;
• Automatic Data Management: The software supports one-click saving of test parameters, query of historical data, and automatic generation of test reports (including qualified/unqualified statistics and parameter curves). It can directly export reports in Excel/PDF format without manual data organization, greatly improving test efficiency.

3. System Configuration and Technical Parameters of the LISUN LEDRACK-100W192P LED Driver Online Test Solution
3.1 System Configuration
The LISUN LEDRACK-100W192P LED Driver Online Test Solution is composed of four core components. Each component works together to realize automatic and standardized aging testing. The specific configuration is as follows:
• Main Body of the LED Driver Online Test Solution: It adopts a steel structure frame with a spray-painted surface, which is aesthetically pleasing and corrosion-resistant. It is equipped with 192 independent test stations (the “192P” represents 192 stations). Each station has an independent power interface, load interface and parameter collection module, supporting simultaneous testing of 192 LED drivers and meeting the needs of large-scale production. The station layout is clear, and the operation panel is clearly marked, allowing workers to quickly plug and unplug samples and reducing operation difficulty;
• Aging Control System: It includes an industrial computer and dedicated aging test software. The software interface supports Chinese-English switching and has a simple operation logic. Workers only need to select a preset test plan (such as “Home LED Driver Aging Plan” and “Commercial LED Driver Aging Plan”) to start the test without complex parameter adjustment. The system supports on/off control signal output and relay switch control, and can remotely control the start and stop of the online test solution, reducing manual intervention;
• LED Load Module: It uses a high-precision electronic load chip and can simulate LED loads of different powers and types (such as single-string LEDs and multi-string parallel LEDs). The load parameters can be freely adjusted through software. For example, when testing a 12V/3A constant current driver, the load can be set to 3A constant current mode; when testing a 24V/50W constant voltage driver, it can be set to 50W constant power mode, with a load adjustment accuracy of ±0.1%;
• Temperature Control Device: It is composed of a heating tube, a fan and a K-type thermocouple. It adjusts the internal temperature of the online test solution through a PID temperature control algorithm to ensure temperature uniformity (the temperature difference in the same aging area is ≤3℃). When the temperature exceeds the set upper limit, the fan is automatically started to cool down, preventing the driver to be tested from being damaged due to excessive temperature and ensuring test safety.

3.2 Technical Parameters
The technical parameters of the LISUN LEDRACK-100W192P LED Driver Online Test Solution directly determine its testing capability and application scope. The core parameters are shown in Table 1. From the perspective of parameters, this equipment performs well in test capacity, load accuracy and temperature control range. In particular, the design of 192 stations and power coverage of ≤100W can meet the batch testing needs of small and medium-power LED drivers.
Table 1 Core Technical Parameters of LISUN LEDRACK-100W192P LED Driver Online Test Solution

Parameter Category	Parameter Name	Parameter Specification
Basic Information	Model	LEDRACK-100W192P
	Applicable Products	Small and medium-power LED drivers (power ≤100W), multi-channel LED driver power supplies
	Number of Test Stations	192 independent stations (supporting simultaneous testing of 192 drivers)
Load Performance	Load Modes	CC (Constant Current), CV (Constant Voltage), CR (Constant Resistance), CP (Constant Power), LED (Simulated LED Load)
	Current Adjustment Range	0~10A (independent adjustment for each station)
	Voltage Adjustment Range	0~60V (independent adjustment for each station)
	Power Accuracy	±0.5% FS (Full Scale Accuracy)
Temperature Control System	Temperature Adjustment Range	RT+10℃~60℃ (RT is room temperature, usually 25℃)
	Temperature Control Accuracy	±2℃
	Temperature Collection Method	K-type thermocouple (1 for each aging area, 4 in total)
Control and Data	Control Method	Computer software control (supporting remote start/stop), manual emergency button control
	Data Collection Parameters	Input voltage, output voltage, output current, output power, ambient temperature
	Data Sampling Frequency	1 time/second
	Data Storage	Supporting local storage (computer hard disk), U disk export (Excel/PDF format)
Power Supply and Environment	Operating Power Supply	AC 220V ±10%, 50/60Hz (supporting AC 110V customization)
	Operating Temperature/Humidity	0~40℃, relative humidity ≤85% (no condensation)
	Equipment Dimensions (L×W×H)	1800mm×800mm×1600mm (including stand, subject to actual product)
Standard Compliance	Complied Standards	IEC 62384 “Performance Requirements for DC or AC Electronic Control Gear for LED Modules”, GB/T 24825-2009 “Performance Requirements for DC or AC Electronic Control Gear for LED Modules”

4. Application Scenarios and Advantages of the LISUN LEDRACK-100W192P LED Driver Online Test Solution
4.1 Main Application Scenarios
This LED Driver Online Test Solution is specially designed for finished product testing on the production line and is suitable for batch testing in LED driver manufacturing enterprises. The specific application scenarios are as follows:
• Factory Inspection Link: At the end of the LED driver production line, each batch of products (e.g., 192 units) is connected to the online test solution for an 8-hour aging test. Products that pass the test are labeled as “qualified” and shipped, while unqualified products are marked as “to be repaired”, preventing defective products from entering the market. For example, an LED driver factory has a daily output of 5,000 units. Using 3 LEDRACK-100W192P online test solutions (with a total of 576 stations), it can complete 3 batches of tests per day to meet production capacity requirements;
• Batch Sampling Inspection Link: According to the requirements of GB/T 24825-2009, 5% of products are randomly selected from each batch for a 24-hour long-term aging test to evaluate the overall quality stability of the batch. For example, 50 units are selected from a batch of 1,000 drivers and connected to the online test solution. If all samples pass the 24-hour test, the batch is judged as qualified; if more than 2 failed products appear, the sampling ratio needs to be expanded and the cause of failure analyzed;
• R&D Verification Link: In the R&D stage of new LED drivers, the online test solution is used to simulate different environmental conditions (e.g., high temperature of 60℃ and low temperature of -10℃, which requires a low-temperature module) to test the service life and reliability of the product and provide data support for design optimization. For example, the R&D team found through the online test solution that the output current fluctuation of a certain driver increases when the temperature is above 50℃, and then improved the heat dissipation structure to enhance the high-temperature adaptability of the product.

4.2 Core Application Advantages
Compared with traditional aging test tooling, the LISUN LEDRACK-100W192P LED Driver Online Test Solution has three core advantages, which can significantly improve the testing efficiency and quality control level of the production line:
• Simple Operation, Reducing Labor Costs: The equipment adopts “fool-proof” operation. Workers only need to insert the driver into the test interface and click the “Start Test” button in the software to complete parameter setting and start the test without professional training. The software automatically records data and generates reports, eliminating the need for manual recording and calculation. One worker can manage 2-3 online test solutions at the same time, increasing labor efficiency by more than 50%;
• Standard Compliance, Ensuring Test Effectiveness: It strictly complies with IEC 62384 and GB/T 24825-2009 standards. The load mode, temperature control range and data collection accuracy all meet the standard requirements, and the test results are authoritative and traceable. For example, GB/T 24825-2009 requires LED drivers to operate continuously for 1,000 hours under rated load without failure. Through an 8-hour accelerated aging test, the online test solution can screen out more than 90% of early failed products, and the consistency with the long-term test results required by the standard is more than 95%;
• Efficient Batch Testing, Adapting to Large-Scale Production: 192 independent stations support simultaneous testing of multiple drivers. The daily test volume of a single equipment can reach 768 units (calculated based on 8 hours per batch, 3 batches per day). Compared with traditional tooling (testing 20 units per batch), the testing efficiency is increased by 9 times. At the same time, the equipment supports multi-channel driver testing and can adapt to multi-string LED drivers in the intelligent lighting field, meeting the testing needs of diverse products.

5. After-Sales Support and Maintenance Recommendations
5.1 Comprehensive After-Sales Support
The LISUN LEDRACK-100W192P LED Driver Online Test Solution has been used in the market for more than 10 years. The after-sales team has summarized a wealth of Frequently Asked Questions (FAQ), which are continuously updated through the official website (https://www.lisungroup.cn/products/2027.html). Typical questions that users can query include:
• Fault Type: No output current at a certain station – check whether the interface contact is good and whether the load module is damaged;
• Operation Type: Software fails to collect data – check whether the communication cable between the computer and the online test solution is connected and whether the driver is installed normally;
• Accuracy Type: Excessive temperature control deviation – calibrate the thermocouple and clean the dust on the heating tube.
In addition, LISUN provides equipment calibration services and can issue calibration certificates complying with IEC 62384 standards to ensure that the online test solution maintains testing accuracy for a long time. The equipment has a one-year warranty period, during which free maintenance and replacement of parts are provided.

5.2 Daily Maintenance Recommendations
To extend the service life of the LED Driver Online Test Solution and ensure testing accuracy, it is recommended to perform daily maintenance in accordance with the following requirements:
• Daily Maintenance: Before testing, check whether the equipment power supply and communication cable connections are normal; clean the dust and debris on the test interface to avoid poor contact; check whether the fan of the temperature control device rotates normally to prevent temperature control failure;
• Weekly Maintenance: Use a multimeter to calibrate the voltage/current collection accuracy of 1-2 stations. If the deviation exceeds ±1%, calibration should be performed through software; clean the heat dissipation holes inside the online test solution to avoid dust accumulation affecting heat dissipation;
• Monthly Maintenance: Check whether the terminals of the load module are loose and fasten the loose terminals; calibrate the temperature collection accuracy of the K-type thermocouple. The thermocouple can be placed in a standard constant temperature box, and the temperature displayed by the online test solution is compared with the actual temperature. Adjust in time when the deviation exceeds the limit.

6. Conclusion
The aging test of LED drivers is a key link in the quality control of the production line, and the standardized and automatic LED Driver Online Test Solution is the core equipment to ensure testing efficiency and accuracy. By integrating multi-mode load, automatic control, precise temperature control and data collection functions, the LISUN LEDRACK-100W192P LED Driver Online Test Solution strictly follows international and national standards, effectively solving the pain points of traditional aging testing and providing an efficient and reliable finished product testing solution for LED driver manufacturers.

From a technical perspective, this equipment covers the testing needs of small and medium-power LED drivers, and the design of 192 stations and multi-load modes is suitable for large-scale production. From the perspective of application value, its simple operation and automatic data features reduce labor costs, and the standard-compliant testing process ensures product quality, helping enterprises improve market competitiveness.

Tags：LEDRACK , LEDRACK-100W192P