DMC worked with a tier one manufacturer of large automotive rechargeable lithium-ion battery packs to develop an automated system for end of line functional testing. The resulting test platform took the manufacturer directly from hand-testing to full automation in less than 4 months. DMC was responsible for designing, programming, building, and testing the system which is now in use in the client’s R&D and production facilities. The system architecture is based on National Instrument’s modular PXI hardware platform running a custom LabVIEW application.
DMC started this project by working closely with the Client to (i) analyze their entire manual test procedure, consisting of dozens of independent test routines, and (ii) understand the operator and device safety issues involved with handling the high current and voltages required for testing. After completing these assessments, DMC was able to design a safe and completely automated test station hardware solution to meet the Client’s needs. As part of the design, DMC selected major components and instruments based on the requirements of each individual test procedure, balancing system performance, accuracy, reliability, flexibility, and cost. Upon finalizing the design, DMC coordinated and managed the system build using a contract manufacturer. A custom LabVIEW application was designed to control the test system, including test recipe and parameter editing and storage, control of all system relays and instruments, built-in CAN communications with on-board battery diagnostic systems, monitoring of the integrated safety and interlock system, and storage of the resulting test data.
>> For more information on EV Battery Pack and BMS Testing see this DMC White Paper.