Battery Test Benches –
High Voltage Battery Test Systems
Modular and scalable
Customized system solutions
Battery test benches & systems
for development and production applications
The increasing use of electric drive systems in both the automotive industry and modern transportation requires the development of new high-performance energy storage systems.
Performance parameters:
- Power ranges: 10 to 180 kW,
- Voltage range: up to 1,000 V
- Test currents: up to 480 amps
- High energy efficiency due to regenerative capability
Testing battery performance parameters
- Charge and discharge with four-quadrant power supplies
- Battery sensing for fast and accurate charge and discharge cycles
Cell quality and isolation testing
- Short circuit detection
- Measurement of leakage current and insulation measurement
- High voltage isolation test up to 6 kV with automatic ground switching of all signal lines
Battery Management System (BMS) test
- Support of wired and wireless interfaces: CAN bus, Modbus, I2C, Bluetooth, WLAN
- Digital or analog signals
Battery Management System
Customized system solutions for whole battery pack testing including battery management electronics
- Open interfaces for communication with the BMS to query the battery status, e.g. for charging cycles or cell voltages
- Support of different standards: Bluetooth, WLAN
- Support of different interfaces: CAN bus, Modbus, I2C
- Digital or analog signals
Our preconfigured
Battery Test Systems and Test Benches
A preconfigured battery test bench enables efficient, precise and user-friendly battery testing, which can be beneficial in research and development as well as industrial production.
P280-200 Battery Test System
The P280-200 battery test system is a stand-alone system that can be used in both the development and production of battery modules and systems.
Single place tester model P480-500
Power class up to 480 V / 500 A
Insulation test up to 6 kV
Single/multi place tester model P480-1000
Power class up to 480 V / 1000 A
Insulation test up to 6 kV
Single/multi station tester model P1000-500
The P1000-500 battery test system is a scalable high-performance test system consisting of a central power unit with power supplies and electronic loads and up to four mobile test stations. The test stations contain the necessary measurement technology and the PC terminal with touch screen for operating the test bench. The modular concept, the shared use of the power supplies and loads, and the regenerative capability of the loads enable extremely cost-efficient operation of the entire test system – both in the development and production of battery systems. The required powers are switched to the respective test station via a specially developed high-power switching matrix.
Power class up to 1000 V / 500 A
Isolation test up to 6 kV
Some of the preconfigured features
Measurement of any analog signals (analog IO)
Providing digital IO signals
Floating relay contacts
Temperature measurements
Insulation monitor test
Individual testing and interconnection of the battery modules
Communication with the DUT via CAN, Modbus, Bluetooth or WLAN
2D/3D barcode scanner / RFID reader / control label printer
Modular system hardware of the battery test benches
Test Data Management Test Reporting
Free configurable test reports and certificate generation
High power matrix with power classes up to 1000 V / 500 A
The central power unit
Variable connection technology with high current and high voltage cables
For different battery systems and cable sets
Preconfigured battery test benches
offer advantages:
#1
Time saving:
Due to the pre-configuration, all necessary settings and parameters are already prepared, which significantly reduces the setup time and accelerates the test operation.
#2
Easy handling:
Preconfigured test stands are usually designed to be user-friendly and require less technical expertise to operate. This makes them easier to use by different employees.
#3
Reliability:
Prior configuration and test runs ensure higher reliability and precision of the tests, as potential sources of errors can be identified and eliminated in advance.
#4
Standardized testing:
Preconfigured test benches enable standardized test procedures that deliver reproducible results, ensuring comparability of tests across different time periods or locations.
#5
Increased efficiency:
The predefined configuration minimizes human error and ensures a smooth test flow, resulting in overall higher efficiency in terms of time, resources, and costs.
#6
Quick customization:
Preconfigured test stands can often be easily adapted to specific requirements or test conditions, allowing flexibility in performing different tests.
#7
Documentation:
Prior configuration facilitates documentation of tests performed and results, which is important for quality assurance and reporting purposes.
#8
Easy integration:
Preconfigured test stands can often be seamlessly integrated into existing test environments or processes.
Testing methods and standards
Which standards and test methods do you
do you need or want to implement?
| Standards and test methods |
|---|
IEC 62660 test procedures and acceptance criteria for secondary lithium cells in electric cars. |
ISO 12405-4 Performance tests for Li-ion battery packs and systems |
UN38.3 Transport of Li-ion batteries |
UL 1974: Creating a Safe Second Life for EV Batteries |
Service and Support for Your Battery Test Bench
Creation of a flexible and modular test system
.
Customer-oriented test system design
Delivery to site
Installation and commissioning on site
Service and training
Regular maintenance and calibration
TestMaster - the toolbox for your testing requirements
TestMaster is a flexible software for all test benches. Configurable test bench control and test automation for real-time and HIL test systems, function tests, qualification tests, durability tests, software and hardware validations, production tests.
TestMaster®
Integrierte Software – Leistungsfähig und zukunftssicher
Voll- oder halbautomatischer Prüfbetrieb und die manuelle Bedienung zur Wartung und Einrichtung des Prüfsystems erfolgen unkompliziert über die kundenspezifisch konfigurierte TestMaster-Software. Die zukünftige Anpassung von Prüfabläufen und -berichten ist flexibel jederzeit durch den Betreiber möglich.
Our partner for demanding high-voltage contactors
In our high-performance P480-1000 battery test system, we rely on high-voltage contactors from Schaltbau for switching the discharge and charging currents.
Schaltbau
