Burn-In Testing Using Regenerative AC Loads

Burn-In Testing Using Regenerative AC DC Loads Blog

Resistive vs. Regenerative AC Loads for Burn-In Testing

Burn-in testing is a critical step in ensuring the reliability and durability of electronic products across industries like energy, automotive, telecommunications, and more. By subjecting components to prolonged operation under elevated stress conditions, burn-in testing helps identify early-life failures and validates product quality before deployment.

Traditionally, resistive loads have been the mainstay for burn-in tests, offering simplicity and affordability. However, regenerative electronic loads have emerged as advantageous especially for high power or high volume applications, delivering unparalleled energy efficiency, precision, and long-term cost benefits.

Types of Testing: R&D vs. Production 

Burn-in testing can occur during both the R&D and production phases of a product’s lifecycle, each serving distinct purposes:

  • R&D Burn-In: Focuses on product design and reliability evaluation by testing limits under varied and extended conditions. Failures identified here inform design improvements.
  • Production Burn-In: Ensures quality control for mass-produced products, identifying early failures and verifying performance under standardized, high-volume testing conditions.

The Role of Regenerative Electronic Loads

Regenerative electronic loads elevate burn-in testing by recycling energy back into the power grid, significantly reducing operational costs and environmental impact. Key Benefits Include: 

  • Energy Recycling: Recover up to 90% of the energy consumed during testing.
  • Reduced Cooling Requirements: Minimize HVAC costs by generating less heat.
  • Dynamic Testing Capabilities: Simulate complex and real-world load profiles with programmable options.
  • Cost-Effectiveness: Offset higher upfront costs with long-term operational savings.
  • Scalability: Adapt easily to diverse applications and large-scale operations.

Burn-In Application Examples 

  1. Energy Storage Systems (ESS): Burn-in testing ensures lithium-ion battery packs can handle prolonged charge/discharge cycles and varying temperatures.
  2. Electric Vehicle Electronics: Key EV components like inverters and DC-DC converters are tested under sustained electrical and thermal loads.
  3. Power Supplies: Validates the performance of UPS systems, military power supplies, and IT infrastructure under power fluctuations and surges.
  4. Solar Inverters: Tests durability under environmental stresses and grid fluctuations to ensure reliable renewable energy conversion.

A Comparative Look: Resistive vs. Regenerative Loads

AspectResistive LoadsRegenerative Loads
Energy UsageConverts energy to heatRecycles energy back to the grid
Cooling RequirementsHigh HVAC demandsMinimal cooling needed
Cost ImplicationsHigh operational costsReduced long-term expenses
Environmental ImpactHigh carbon footprintEnhanced sustainability
Testing PrecisionStatic load profiles onlySupports dynamic, programmable profiles

Download the Application Note

Our application note, Burn-In Testing Using Regenerative Electronic Loads, offers a comprehensive guide to leveraging this advanced technology. 

Key takeaways include:

  • Analysis of energy savings and cost reductions
  • Practical examples of real-world applications
  • Tips for selecting the right regenerative load for your needs
Burn-In Testing Using Regenerative AC DC Loads Blog

Resistive vs. Regenerative AC Loads for Burn-In Testing

Burn-in testing is a critical step in ensuring the reliability and durability of electronic products across industries like energy, automotive, telecommunications, and more. By subjecting components to prolonged operation under elevated stress conditions, burn-in testing helps identify early-life failures and validates product quality before deployment.

Traditionally, resistive loads have been the mainstay for burn-in tests, offering simplicity and affordability. However, regenerative electronic loads have emerged as advantageous especially for high power or high volume applications, delivering unparalleled energy efficiency, precision, and long-term cost benefits.

Types of Testing: R&D vs. Production 

Burn-in testing can occur during both the R&D and production phases of a product’s lifecycle, each serving distinct purposes:

  • R&D Burn-In: Focuses on product design and reliability evaluation by testing limits under varied and extended conditions. Failures identified here inform design improvements.
  • Production Burn-In: Ensures quality control for mass-produced products, identifying early failures and verifying performance under standardized, high-volume testing conditions.

The Role of Regenerative Electronic Loads

Regenerative electronic loads elevate burn-in testing by recycling energy back into the power grid, significantly reducing operational costs and environmental impact. Key Benefits Include: 

  • Energy Recycling: Recover up to 90% of the energy consumed during testing.
  • Reduced Cooling Requirements: Minimize HVAC costs by generating less heat.
  • Dynamic Testing Capabilities: Simulate complex and real-world load profiles with programmable options.
  • Cost-Effectiveness: Offset higher upfront costs with long-term operational savings.
  • Scalability: Adapt easily to diverse applications and large-scale operations.

Burn-In Application Examples 

  1. Energy Storage Systems (ESS): Burn-in testing ensures lithium-ion battery packs can handle prolonged charge/discharge cycles and varying temperatures.
  2. Electric Vehicle Electronics: Key EV components like inverters and DC-DC converters are tested under sustained electrical and thermal loads.
  3. Power Supplies: Validates the performance of UPS systems, military power supplies, and IT infrastructure under power fluctuations and surges.
  4. Solar Inverters: Tests durability under environmental stresses and grid fluctuations to ensure reliable renewable energy conversion.

A Comparative Look: Resistive vs. Regenerative Loads

AspectResistive LoadsRegenerative Loads
Energy UsageConverts energy to heatRecycles energy back to the grid
Cooling RequirementsHigh HVAC demandsMinimal cooling needed
Cost ImplicationsHigh operational costsReduced long-term expenses
Environmental ImpactHigh carbon footprintEnhanced sustainability
Testing PrecisionStatic load profiles onlySupports dynamic, programmable profiles

Download the Application Note

Our application note, Burn-In Testing Using Regenerative Electronic Loads, offers a comprehensive guide to leveraging this advanced technology. 

Key takeaways include:

  • Analysis of energy savings and cost reductions
  • Practical examples of real-world applications
  • Tips for selecting the right regenerative load for your needs