The DMC BPT is a fully automated, feature-rich, platform-based test solution designed to meet the needs of battery production test regimens, including today’s industry standards and tomorrow’s emerging requirements.
The DMC BPT is built with care and attention to the needs of all users and stakeholders in the production testing process:
DMC has been designing and building battery test equipment since 2008, and DMC’s BPT3 solution is the culmination of that domain knowledge and expertise.
Our experience in pack, module, and BMS/BMU testing across the development & validation and production & rework testing phases of the battery lifecycle can add value and vision to your entire approach to battery testing.
DMC uses the same foundational Battery Test Platform modules to configure both validation (lab) and production (End-of-Line) test stations for our clients — magnifying NRE value and creating standardization across test domains.
DMC’s BPT Platform takes a compositional approach to battery testing, assembling collections of interconnectable hardware building blocks (including both COTS devices and DMC purpose built modules) to create modular, scalable full-scale test carts and stations.
DMC has designed several common BPT models for standard battery test scenarios and can custom tailor a configuration anywhere on the capability spectrum to match your specific needs.
The DMC BPT Platform allows you to test your battery pack or battery module today, and be ready for the changes of tomorrow. With reliable battery test hardware based on a variety of standard rack-mount instruments and NI’s PXI and cDAQ platforms, you can readily expand your system for the evolving battery test needs of the future.
DMC’s BPT Platform includes support for common battery cycler manufacturers and models, including NHR, Electro-Automatik, and more. Whether internal or external to your BPT test station, your battery cycler will be plug-and-play and swappable — thanks to the BPT’s flexible hardware abstraction layer and configurable software plugins. DMC can even expand your cycler capabilities using our BPT platform’s high-power switching, MUX, and connection modules.
DMC’s BPT Platform software allows users to quickly generate test sequences to validate battery production. The platform abstracts the detailed intricacies of test into simple sequence step “building blocks” that Test Engineers can use without extensive programming knowledge.
The Test Executive Software offers simple, intuitive user interfaces for operators, while providing ample flexibility and control for engineers to configure and customize the system for their needs.
Have specific user interface requirements? The BPT software is customizable to the exact end user experience and workflow your company needs.
The BPT’s plugin framework combined with a Hardware Abstraction allows for easy addition of new hardware or models of battery cyclers, power supplies, DMMs, and other instrumentation as your production scales and test requirements change.
Reduce your time spent managing multiples copies of test sequences by writing your test script once. Use the abstraction layer to execute the same test script on different BPT test stations that connect to different types of battery cyclers. Parameterize your test sequence to run the same test on two different batteries that have different cell configurations, test limits, or other parameters.
Test with peace of mind by verifying test system integrity using the equipment’s Self-Diagnostics tool. This feature can quickly identify equipment failures and provide your team the insights to act and reduce downtime.
Ensure proper testing and traceability with BPT’s workspace configuration management that provides a documented link between the input configuration files that go into test and the output data. Integrate with NI SystemLink to easily manage all your test assets and data in one central location.
The DMC BPT is highly customizable. Typical features come standard in our base BPT package, with plenty of additional feature options to configure your BPT solution to your specific needs. If you need a feature not listed, just ask! The answer is almost certainly “Yep we can do that!”
Feature or Module
Details
Config
System Structure
Half or Full Height Server Rack, Casters, Forklift Compatible / Reinforced Base, 120 VAC input power
Standard
Controller
High Performance Rack Mount PC, SSD, Windows OS
PC Peripherals
Dual Displays, Monitor, Keyboard, Mouse, System Restore Recovery Drive
Primary Instrumentation Chassis
NI PXI Chassis
Supporting Instrumentation Chassis
NI Compact DAQ Chassis
Medium Voltage Measurement Lines
Primary instrumentation measurements (300 VDC, 2 A)
High Voltage Measurement Lines
High Voltage instrumentation measurements (1000 VDC, 5 A)
Optional
Low Power Lines
Low Power device (source / load) integration (300 VDC, 5A)
Current Shunt Monitor Module
Continuous, high-speed monitor of Low Power lines (16-bit, 15 kS/s per ch)
Dry Contact Lines
Dry Contact Lines - source / return (300 VDC, 5 A)
Medium Power Module
Medium Power device integration (300 VDC, 30 A)
DUT CAN Integration Module
DUT CAN ports (HS / LS / FD), Broadcast CAN per Database, UDS, J1939, XCP / CCP, other protocols as required
Advanced DUT CAN Integration
Application Layer Protocols - Unified Diagnostic Services, J1939, XCP / CCP, DUT flashing, security protocols, EEPROM writing, etc.
Hipot Test Module
0.2 kV to 5 kV DC or AC, 50 VA continuous, Insulation / Withstand testing
PXI Digital Multimeter
1000 VDC, +/-3A, 1.8 MS / sec, 7.5 Digit Resolution, Functions: Voltage, Current, Resistance, Diode
Programmable DC Power Supply
0-80 VDC, 0-28A (limited to 5A per Low Power Line), 750W total
Ground Bond Test Module
Instrumentation for medium current (~25A) ground bond verifications
ACIR Test Module
Instrumentation for performing ACIR measurements
High Power Contactor Box
Contactors for high power distribution from cycler to DUT
Ambient Environment Sensor
Ambient temperature / humidity sensor
Standardized DUT Connector
VPC ICON 160 pin connector, Duraline High Power Connectors
DUT Wiring Harnesses
Low power and high power harnesses between tester and DUT
Safety / Interlock System
Tester safety Interlock circuit, safety controller, Estops, remote interlock input/output for facility / equipment safety integration
Barcode Scanner
Barcode scanner and associated system workflow integrations
Battery Cycler
DMC BPT integrates with any Cycler. Use your existing one, or DMC can recommend and include a new one to meet your power requirements
Test Control Application
DMC BPT Software Package: Automated Test Mode, Manual Test Mode, Device Driver Packages, Logging and Reporting, etc.
User Interfaces / User Workflows
DMC BPT GUIs for battery production test, workflows tailored per user role (operator, technician, test engineer, etc.), w/ enforced permissions
Test Sequencing Framework
NI TestStand
Advanced Self Diagnostics
Suite of automated self-diagnostic routines to help verify tester health and diagnose/isolate potential test system hardware faults
MES / Database Integration
Publish test results to client specific MES or hosted database
NI SystemLink Integration
Data Management, Test Asset Management, Automated Data Analysis Pipelines, Web Based Dashboards to Monitor Testers, etc.
Your Custom Requirements
DMC BPT is highly customizable. If you need a feature not listed, just ask! The answer is almost certainly “Yep we can do that!”