Testing Solutions for Battery Production

23 April 2012 - To meet the needs for continuous quality assurance within the production of batteries FuelCon introduced a modularized cell tester and a end-of-line tester for completely assembled batteries. The cell test unit is able to check the parameters of the incoming battery cells before assembling into the battery housing.

The cell test unit allows cell adaptation, cell identification, checking of electrical parameters such as OCV, impedance or voltage-current characteristics, classification including pass-fail decisions and data exchange with a manufacturing data base.

Being a part of the production line, the end-of-line test unit provides control over all relevant battery parameters including weighting, isolation check, electrical performance test as well as testing and calibration of the battery management system (BMS) and final classification.

Depending on the required cycle times within the assembling process, the test procedure including the cell or battery adaptation can be realized in several automation steps from manual operation, semi-automated procedures up to a fully automated test run.

To meet the typical customer requirements FuelCon offers a range of modules for respective production equipment.  For identifying the test items the units can be equipped with bar- or data-matrix code identification. The test unit control system is interfaced with the manufacturing data base to exchange relevant information about test item and test run.

For adaptation of the power and control interfaces between test item and test unit FuelCon offers customized solutions to meet all safety and automation requirements. For operation, visualization and state information each test unit is equipped with an operator panel. These panels allow single-touch operation of the unit or fully-automated test runs.

Customized performance tests are realized by integrated charge-discharge channel that provide the possibility of standard tests like pulse-power- or capacity tests or fully customized performance tests. These test are synchronized with FuelCon’s proprietary TrueData-BMS gateway. This module organizes entirely real time communication with the BMS including rest bus simulation, firmware flashing, test of BMS in- and outputs and functionalities as well as calibration and isolation tests.

FuelCon's cell test unit and EOL test stations are realized as stand-alone rigs or integrated into fully automated assembling and transfer lines.

From April 23 – 27, FuelCon is presenting its testing solutions and products at the Hannover Messe 2012.