Assembly and Test Facility for Innovative Battery Management
Everything Under Control, even with Last-Minute Changes
Reliable battery control: Battery Management Controller
The lithium-ion cells used in electric vehicles perform at their best when they are permanently monitored, measured, and controlled. These tasks are performed by the vehicle’s Battery Management Controller (BMC). As a control unit, the BMC processes measurement data from the battery cells and helps the vehicle use the battery as efficiently as possible. The BMC collects information on the charge level, health status, temperatures, and safety-related aspects.
Pioneer in battery management for electromobility
We already built testing facilities for e-mobility solutions when the field was still in its infancy. Together with our customers, we gained experience and broadened our knowledge, making us today’s leading manufacturer of assembly lines and testing systems for the production of rechargeable batteries. We also know more about high-current systems than almost anyone else.
We developed, designed, and built an assembly and test system for a high-end sports car company. It’s task is the fully automated assembly of the GN2 control unit for the controller and its integration into the BMC. Two test systems and an end-of-line tester check at six stations whether the finished product, the “Battery Management Controller extended” (BMCe), thoroughly fulfills all quality specifications. For this project, we agreed on the following benchmark with our customer: 100% perfection on all 134 test characteristics – including complex continuity tests and resistance measurements in the micro-ohm range or insulation measurements up to 2,500 volts – with a maximum takt time of 30 seconds per BMCe.
“Continuity testing in the micro-ohm range requires a great deal of expertise. We have to perform a repeatable, stable measurement over the entire batch size. That’s where we can showcase our attention to detail and commitment to quality.”
Precise, safe, at the right takt
E-mobility is continuing to gain ground. MARQ4 Automation has been part of it from the very beginning. This gave us a leading edge in the development and production of an assembly and test system for battery management commissioned by a well-known sports car manufacturer. Armin Braun, our Head of Business Development, explains what makes the system so special and why we keep engineering it even after the start of production.
Our customers’ wishes are our focus
As required by the customer, we will manufacture and test several million units over the entire production period. At the same time, we keep in mind that adjustments may have to be made during ongoing production.
For example, a plug connection may need to be rotated by 90 degrees, as in this case, or an additional sensor may be required to ensure optimum quality. No problem! Our claim is to always find a suitable solution for every challenge.
“Sometimes changes seem like a trivial matter at first, but ultimately necessitate major adjustments to the system. But this is exactly what makes our work so appealing. We develop solutions based on our years of experience, our specialized expertise, and our obsession with precision, in order to meet our customers’ demands quickly and flexibly.”
The greatest challenge in the development and construction of the system were the extraordinary dimensions of the components. This is because their enormous weight and special size have an impact on handling within the assembly and testing line. We recalculated the robot modules and the logistics behind them, which enabled us to move each component precisely and safely within the specified takt time. After all, the more than man-sized robots must move payloads of up to 300 kg in a very confined space.
Full Simulation of All Robots
For optimum takt times and maximum safety
In the planning phase of the end-of-line tester, we created a virtual simulation of the takt time and the entire behavior of the three robots to identify what was feasible in terms of handling the large and heavy components. From this, we calculated exactly how we had to configure the interaction between the robots and the system in order to achieve the desired takt time without compromising on optimum safety.
Additional test highlights
- Complex conductor connections in the micro-ohm range
- Insulation measurement on the component with 2,500 volts
- Testing of all additionally installed components such as relays and sensors
- Application and verification of warning stickers using camera sensors
- High-voltage measurement and 800 volt test on the component in operation (driving)
- Gas leak test
We think ahead and are always breaking new ground to offer our customers something special – discover more exciting reference systems!