October, 2024


www.us - tech.com Demand for Testing in the World of Electric Mobility Continued from previous page


testing — wedge (ultrasonic) or laser bonding test — a crucial part of the manufacturing process. A key factor to check is the connection resistance: precise measurements in the mil- liohm or microohm range are required to ensure that connections are secure. A missing or faulty connection can impair the battery’s efficiency and, over time, lead to serious fail- ures, including the risk of fire. While AOI might seem like an easy


option, it can’t detect issues in the intercon- nections between cells (bonding test). AOI essentially captures an image of the bonding and uses algorithms to judge its quality. To meet the requirements of


high-volume production, using an electrical flying prober is the most effective approach. The most advanced flying prober can perform extremely accurate par- allel Kelvin tests on more than 16 cells at once, reaching speeds of over 2,000 cells per minute. These systems are capable of


measuring wedge bonding resist- ance with great precision, detect- ing values as low as 10 µW with a resolution of 0.5 µW. This level of accuracy ensures consistent and reliable results, along with full traceability for each connection. To meet the increasing


demand for testing connections within battery packs, Seica has developed a new range of flying probe systems: Pilot BT, Pilot BTV, and Pilot H4BT. The Pilot BT system can perform precise parallel Kelvin tests on more than 32 cells simultaneously from the TOP side of the battery pack, reaching speeds of nearly 4,800 cells per minute at full capacity. It features a large test area (1,200 x 1,200 mm) and uses a Bosch sys- tem for battery handling. For more complex battery


packs that require simultaneous access from multiple sides, Seica has introduced the Pilot BTV (Vertical Battery Tester), a flying probe system that provides auto- matic access on three sides. This is particularly useful for “double” battery packs that need bonding tests on both sides and access to the BMS on the top side. For prototype labs or produc-


tion lines with a high mix of products and medium volumes, Seica offers the Pilot H4 BT. This system has four independent axes for fast and parallel testing of two bondings at once, with a test area of 800 x 540 mm and a speed of over 600 tests per minute.


Battery Management System The BMS is a key compo-


nent, crucial for the performance, reliability, and longevity of bat- teries. To ensure each BMS meets its specifications, a com- plete functional test is essential, which involves simulating the actual operating conditions the BMS will face. The recommended method is


See at electronica, Hall B2, Booth 429


to use cell simulators capable of generating a floating, programmable voltage between 0


and 5 volts, mimicking the cell under normal, under-voltage, and over-voltage conditions. Since even minor voltage changes (fractions of a millivolt) can significantly impact the cell’s State of Charge (SoC), the simulator needs to deliver precise voltage and accurate- ly measure the actual output. To test the BMS’s temperature sensing


Mini 200 ACIR test system.


function, which typically relies on NTC (neg- ative temperature coefficient) or PTC (posi- tive temperature coefficient) thermistors, you’ll need a tool that can provide variable resistance across different ranges. In addi- tion, full performance testing often requires Continued on next page


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