Initial Situation
A manufacturer from the industrial automation sector approached TPS Elektronik with a pressing challenge:
its aging power control unit no longer met modern EMC (electromagnetic compatibility) and electrical safety requirements. The company lacked in-house expertise and access to professional EMC testing facilities.
The previous supplier had failed to provide reliable EMC/EMI testing support, and the prototype consistently fell short during regulatory evaluations. High levels of interference made CE approval impossible. In addition, no structured documentation or test records existed.
The customer required:
- Guidance on how to test electromagnetic compatibility during the redesign phase.
- Access to accredited EMC and EMI testing services in line with international standards.
- A reliable testing partner for conducted, radiated, and immunity evaluations.
- Integration of electrical safety testing and validation procedures to meet CE and IEC regulations.
The TPS Solution
TPS Elektronik applied a structured approach that combined engineering redesign, pre-compliance testing, and collaboration with accredited laboratories.
1. Redesign for EMC Compliance
- Developed a new circuit and optimized PCB layout to minimize emissions.
- Applied design strategies aligned with international EMC guidelines to ensure stable behavior.
2. Comprehensive EMC Testing
- Guided the customer through every step — from pre-compliance checks to full certification.
- Conducted extensive radiated and conducted emission tests.
- Coordinated with accredited labs to perform complete EMC and EMI testing in compliance with global standards.
3. Advanced Verification and Immunity Evaluation
- Verified product immunity against external disturbances to improve long-term reliability.
- Delivered complete test documentation and recommendations for future product versions.
4. Electrical Safety Integration
- Performed detailed electrical safety tests covering insulation, grounding, and fault behavior.
- Validated the final design through multiple test cycles according to CE and IEC safety requirements.
Results
The collaboration between TPS Elektronik and the customer led to measurable success:
- Full regulatory compliance: The redesigned unit passed all EMC and electrical safety evaluations.
- Faster certification: Structured testing and documentation shortened approval time by around 30 %.
- Improved reliability: System stability increased, with interference issues reduced by more than 40 %.
- Knowledge transfer: The customer gained practical know-how for future EMC and safety design processes.
Conclusion
This project demonstrates TPS Elektronik’s expertise in delivering integrated EMC testing and electrical safety testing solutions for industrial power equipment.
By combining engineering know-how with accredited testing partnerships, TPS Elektronik ensured compliance, reduced certification time, and improved long-term reliability.
The result: a CE-approved, future-ready product line — and a strengthened partnership built on trust, transparency, and technical competence.
