Assembly and testing system for innovative battery management.
Everything under control, even with last-minute changes
Reliable control of batteries: Battery Management Controller
The lithium-ion cells used in electric vehicles perform at their best when they are constantly monitored, measured and controlled. These tasks are performed in the vehicle by the Battery Management Controller (BMC). As a control unit, the BMC processes measurement data from the battery cells and supports the vehicle in using the battery as efficiently as possible. The BMC collects information on the state of charge and ageing, temperatures and safety-relevant aspects.
PIONEER IN BATTERY MANAGEMENT FOR ELECTROMOBILITY
We were already building testing systems for e-mobility solutions when this segment was still in its infancy. Together with our customers, we have gained experience, deepened our knowledge and are now leaders in assembly systems and test systems for battery production. We also know more about high-current systems than almost anyone else.
We developed, designed and built an assembly and testing system for a large automotive group from Germany, which fully automatically assembles the GN2 control unit for the controller and integrates it into the BMC. Two test systems and an end-of-line tester check at six stations whether the resulting Battery Management Controller extended (BMCe) fully meets all quality specifications. Our benchmark and that of our customer: 100% perfection for 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 cycle time of 30 seconds per BMCe.
Precise, safe, in the right rhythm
E-mobility continues to gain ground. We at MARQ4 Automation have been involved right from the start. We also benefited from this head start in know-how when developing and designing an assembly and testing system for battery management for a well-known German manufacturer. Our Head of Business Development Armin Braun explains what makes the system so special. And why its engineering continues for us even after the start of production.
Customer wishes are our focus
According to customer requirements, we will manufacture and test several million units over the entire production period. In doing so, we keep in mind that there may be requests for adjustments during ongoing production.
For example, if a plug connection needs to be rotated by 90 degrees, as shown here, or an additional sensor is required to ensure optimum quality. No problem, because our aim is to always find a suitable solution for every challenge.
"Heavyweight champion"
The biggest challenge in the development and design of the system was the extraordinary dimensions of the components. This is because their impressive 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 in order to be able to move each component precisely and safely within the specified cycle time. After all, the robots, which are more than a man's height, have to move loads of up to 300 kg in a very confined space.
Full simulation of all robots.
For optimum cycle times and maximum safety.
During the planning phase of the end-of-line tester, we virtually simulated the cycle time and the complete behavior of the three robots to ensure what is feasible in terms of handling the large and heavy components. As a result, we calculated exactly how we had to design the interaction between the robots and the system in order to achieve the desired cycle time and ensure optimum safety at the same time.
Further 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 scanning of warning stickers via camera sensors
- High-voltage measurement and 800 volt test on the component while driving
- Gas leak test
Even more top projects
We think ahead and are always breaking new ground to offer our customers something special - discover more exciting reference systems.
Innovative battery management:
Everything under control - even with last-minute changes
Automatic component coding and testing
Automatic component coding and testing. For perfect rotation