EV Battery Module PACK End-of-Line (EOL) Testing System

1. Equipment Overview

The Battery Module PACK End-of-Line (EOL) Testing System is a fully integrated solution designed to validate the quality, safety, and performance of battery modules and PACKs at the final stage of production. It performs comprehensive tests to ensure the product meets specified standards before shipping, covering electrical, thermal, and mechanical parameters, as well as communication functionality.

2. Key Features

Comprehensive Testing: Combines electrical performance, communication, insulation, and safety tests.

High Precision: Accurate measurement of voltage, current, and resistance.

Multi-Protocol Support: Compatible with common communication standards (CAN, RS485, etc.).

Automated Operations: Streamlined processes for fast and efficient testing.

Customizable Profiles: Configurable test sequences based on customer requirements.

3. Technical Specifications

3.1 Electrical Performance Testing

Voltage Measurement Range: 0–1,000 V DC.

Accuracy: ±0.05%.

Current Measurement Range: 0–300 A DC (configurable for higher currents).

Accuracy: ±0.1%.

Capacity Range: 10 Ah–500 Ah.

Internal Resistance Measurement:

Range: 0.1 mΩ–1 Ω.

Accuracy: ±0.5%.

Power Capability: Up to 200 kW.

3.2 Communication Testing

Supported Protocols: CAN, RS485, LIN, Ethernet.

Baud Rate: Up to 1 Mbps (CAN).

Data Logging: Monitors communication signals for errors and integrity.

Protocol Customization: Supports proprietary communication protocols.

3.3 Safety and Insulation Testing

Insulation Resistance Test:

Voltage: Up to 1,000 V DC.

Range: 0.1 MΩ–1 GΩ.

Accuracy: ±1%.

Dielectric Withstand Voltage Test (HiPot):

Voltage: Up to 5,000 V AC/DC.

Leakage Current: ≤1 mA.

Short-Circuit Protection Test: Verifies PACK safety mechanisms.

3.4 Functional Testing

Charge-Discharge Testing: Simulates real-world operating conditions.

Programmable Cycles: Up to 10,000.

Dynamic Load Simulation: Replicates operational profiles.

Thermal Behavior: Measures thermal stability under various conditions.

Temperature Range: -10°C to 80°C (optional integrated thermal chamber).

Accuracy: ±1°C.

3.5 Software and Control

User Interface:

15-inch touchscreen HMI with an intuitive design.

Multi-language support (English, Chinese, etc.).

Data Management:

Real-time monitoring with graphical analysis.

Historical data storage for traceability.

Export formats: CSV, Excel, PDF.

Test Programming: Configurable test parameters and sequences.

Remote Access: Ethernet, USB, and Wi-Fi for data transfer and monitoring.

3.6 Mechanical Design

System Configuration:

Modular structure for scalability.

Adjustable fixtures for various module and PACK dimensions.

Capacity: Up to 16 modules/PACKs per cycle.

Dimensions:

Length: 2,000–4,000 mm.

Width: 1,200–2,000 mm.

Height: 2,000 mm.

Weight: 1,500–3,000 kg.

3.7 Safety Features

Overvoltage/Overcurrent Protection: Prevents damage to modules or equipment.

Emergency Stop: Accessible emergency shutdown for operators.

Environmental Monitoring: Includes smoke detectors and temperature sensors.

Certifications: CE, UL, ISO 9001 compliant.

3.8 Environmental Requirements

Operating Temperature: 10–35°C.

Humidity: ≤60% RH (non-condensing).

Power Supply: AC 380V ±10%, 50/60 Hz, 3-phase.

Power Consumption: ≤50 kW.

4. Applications

EV Battery Production: Ensures compliance with quality and safety standards.

Energy Storage Systems (ESS): Validates the performance of grid-scale battery systems.

Consumer Electronics: Assesses battery modules for small-scale applications.

R&D and Quality Assurance: Supports product development and quality consistency.

5. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspect connectors, sensors, and fixtures.

Monthly: Calibrate voltage, current, and resistance measurement systems.

Annually: Perform comprehensive diagnostics and software updates.

Warranty Period:

Standard: 12 months.

Extended: Available upon request.