Hybrid Electric Vehicle Battery Test System

Test Stand

Test Stand

User Interface

User Interface

Battery Pack

Battery Pack

Summary

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.

Customer Benefits

  • Increased testing capacity, flexibility, and accuracy through fully automated functional testing
  • Increased traceability through fully automated reporting and data storage
  • Increased operator safety through an integrated safety and interlock system

Technologies

  • National Instruments LabVIEW 2009
  • National Instruments PXI Hardware Platform
  • National Instruments DAQmx, CAN, DMM
  • GPIB, RS232, RS485, and CAN Communications
  • Pickering PXI High Voltage Relay Banks

Solution

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.

Posted in Test and Measurement, Automotive, Green Technology, Test and Measurement Automation, Test and Measurement Automation

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