Battery Module & Pack Testing

The high-voltage battery is the central component of any electric vehicle. It is also the most expensive and technically critical component in electric mobility. It is therefore of utmost importance to thoroughly test each battery individually for its safety-relevant electrical functionalities before installing it in the vehicle and to maintain the test results in audit-proof documentation. This ensures cost-efficient battery installation and a reliable battery operation.

Reliable test procedures for the verification of safety specifications and functions for high voltage batteries and battery modules.
Audit-proof documentation of all test results as well as all installed components and modules in terms of traceability.
Safety and occupational safety via extensive digital I/O channels for communication with occupational safety components and for integration into functional safety circuits.
Customized solution, the functional scope of which is individually compiled according to customer requirements and test location.

Functional overview

High-voltage insulation tests to identify insulation defects in high-voltage components and cables in accordance with UN standard ECE R100. Intact insulation is a basic requirement for safe handling of the batteries in production and subsequent battery operation.
Leak test of the internal cooling circuits of the battery system. A tight cooling circuit prevents damage caused by leaking coolant, such as a short circuit.
Leak test of the battery housing against incoming liquids (e.g. in case of high water). For safe operation of a high-voltage battery, it is necessary that no liquids can enter through the battery housing. Penetrating water can lead to a short circuit in the battery.
Visual inspection via checklist app or camera system. PRODIS.TrueBattery supports visual commissioning inspection, including photo documentation.
Battery Management System (BMS) diagnostics. The general condition and function check of the BMS is the basis for all further battery tests.
Programming and verification of the vehicle-specific configuration of the battery and updating of the battery management controller (flashing). PRODIS.TrueBattery ensures that the appropriately configured battery is available at the time of subsequent assembly in the vehicle, thus saving valuable takt time.

High-voltage charge test & State of Charge validation cycle ensure that the correct state of charge is read out during subsequent battery operation. This increases the life expectancy of the battery. It also ensures that the HV battery is charged to the correct state of charge required for subsequent transport.
High-voltage charge and discharge tests to detect contact resistances. Thermographic image analysis is used to monitor the temperature distribution in the battery modules in order to identify, for example, faulty contact between the battery modules, which can lead to overheating of the battery.
Validation of the temperature sensors by reference measurements. This test ensures that the safety mechanisms of the BMS for detecting a thermal problem within the battery are functional.
Simulation of fault patterns such as short circuit and connection of external resistors. This test ensures that the safety-related self-test functions of the BMS are working properly.
Simulation of commercially available battery charging stations. This test ensures that the charging infrastructure is correctly identified on the basis of the global standards CCS, GB/T27930/CHAdeMO and that communication between the charging station and the internal charging electronics of the battery functions smoothly.