Over the past 15+ years, the electrification landscape has undergone a dramatic transformation. From the early days of hybrid vehicle prototypes and niche fuel cell applications, we now live in an era where electric vehicles (EVs), grid storage systems, and battery innovation are driving one of the most significant shifts in the energy and transportation sectors.
At DMC, we’ve been at the forefront of this evolution, building robust, scalable, and future-proof battery test solutions for major OEMs, EV startups, and energy labs. As part of our journey, we’ve continued to work with a variety of legacy and cutting-edge battery cycler platforms, including a longtime staple in the industry: the Aerovironment battery cyclers, now rebranded under Webasto Charging Systems following their acquisition.
If you walk into a battery lab or R&D center today, there’s a good chance you’ll still spot AV-900, ABC-150, or ABC-170 cyclers humming away in a corner. These workhorses have been around for years and have built a track record for staying accurate and dependable under heavy use. They’ve been put to the test on everything from older lead-acid cells to the newest high-performance lithium-ion packs, and they’re still getting the job done. The challenge isn’t the hardware—it still performs as reliably as ever, but the built-in software tools haven’t evolved alongside the rapid changes in battery testing. Many of the original integration options now feel dated. The good thing is, modern automation platforms and updated integration methods make it possible to breathe new life into these proven systems.
Modernizing Control & Automation with LabVIEW and TestStand
At DMC, we’ve built dozens of test systems that interface with Webasto/Aerovironment cyclers using a variety of control strategies.
Common strategies include:
- Remote Operation System (ROS) scripting, which requires C-based development, offers basic command-level access—but lacks user-friendly interfaces and extensibility for long-term test programs.
- Legacy DCOM Drivers for Windows applications like LabVIEW have been available but are notoriously outdated, lacking support for modern toolchains and requiring extensive debugging.
To simplify the process, DMC has developed custom LabVIEW drivers, reusable APIs, and scalable frameworks that integrate Webasto cyclers into full-featured test automation platforms.
CAN-Based Communication remains the most effective, open, and performant option for high-speed integration—especially for systems with dual outputs or demanding test sequencing. These DMC solutions are built using NI LabVIEW, TestStand, and CompactDAQ/PXI platforms, often tightly coupled with MES systems, high-speed instrumentation, and safety interlocks.
Whether retrofitting an older AV/ABC cycler or building a new test stand that supports multiple equipment types (Webasto, Bitrode, Chroma, Arbin, etc.), we ensure operator-friendly UIs, data-logging pipelines, and real-time feedback for test traceability and compliance.
DMC has expertise and proven software control routines to support these common Aerovironment/Webasto cycler models:
- MT-30
- ABC-150
- ABC-170 / CE
- ABC-600
- AV900 / 900-EX
Typical Use Cases We’ve Enabled
- End-of-line (EOL) validation of high-voltage EV packs
- Functional verification of Battery Management System (BMS)
- Remanufacturing and warranty diagnostics
- High-throughput cycling for R&D across multiple chemistries
- HiL simulation of charge/discharge behavior with Webasto cyclers
In all cases, we help customers move beyond “bare-bones” PC control to a fully automated, traceable, and scalable test environment.
Should You Build it Yourself or Work with a Partner?
DMC brings decades of expertise, a deep portfolio of turnkey battery test systems, and partnerships with industry leaders like NI, Webasto, and Microsoft. So, whether you’re modernizing a legacy test bench or developing a brand-new validation platform, you don’t need to reinvent the wheel or the driver stack. We’re here to help you accelerate development, reduce risk, and build for scale.
Let’s Talk Battery Test Automation
Want to bring new life to your AV/Webasto cyclers? Looking to scale your test infrastructure with modern tools? Contact us to learn more about how DMC can help you integrate, automate, and future-proof your battery testing workflow.
Ready to take your Test and Measurement project to the next level? Contact us today to learn more about our solutions and how we can help you achieve your goals.