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manufactured product. A case in point is the test process. The
electrical connections between the cells of an EV battery are fundamental to the correct performance and safety of the battery, so testing the bonds is a mandatory step of the battery manufacturing process. One of the most important parameters of
the battery is the bond resistance. This re- sistance value cannot be measured with AOI or X-ray techniques, and the milli- or micro- ohm measurement must be made to the OEM/end user specification. If bonds were missed or defective coming
out of the production process, the efficiency of the battery will be compromised, even though initially it may appear to function normally. Over time however, a missing or defective bond can cause catastrophic fail- ures or even fires. Consider the consequences in the case of
battery-powered passenger planes. While some may suggest that statistical sampling can be done to avoid testing every battery pack coming off the production line, the con-
The Pilot BT can accommodate
diverse battery configurations with its large test area and can handle packs weighing up to 300 pounds.
sequences of not testing every bonding joint are potentially very dangerous, exposing OEMs and battery manufacturers to disas- trous fines and litigation.
Seica’s Pilot BT
Battery management system (BMS) test solution.
cise Kelvin tests of 16 or more cells simulta- neously, achieving production rates of nearly 2,400 battery cells per minute, more than doubling first-generation performance. The integrated measurement instru-
mentation has been designed to provide the electrical test performance required to test to the bonding specification, and can discrimi- nate 10 µW resistor values with 0.5 µW reso- lution and high accuracy, providing reliable, repeatable test with complete traceability. The Pilot BT can accommodate the most
diverse battery configurations within its very large test area (1,050 x 865 mm) and has the capacity to handle battery packs weighing up to 300 pounds. The standard system configu- ration includes a pass-through conveyance by Bosch, but it can also be configured with customer-specified conveyance solutions in- tegrated into completely automated lines. For low- to medium-volume, high-mix
September, 2022 Innovative Testing Solutions for the EV Market For the specific test requirements of this
increasingly high-volume manufacturing process, Seica’s Pilot BT represents a new generation of flying probe test solutions. The Pilot BT is able to perform parallel, very pre-
production environments, Seica’s Pilot H4 BT, with its four independent axes, can per- form fast, true parallel test for two bonds si- multaneously: its advanced measurement system is able to run in parallel mode, per- forming a multiple micro-Ohm test measure- ment (4 wire test) in a few milliseconds. If many different variants of batteries
must be tested in a single day or week, such as two or three different battery pack sets in the same pallet, having two bonding probe configurations per independent head pro- vides tremendous flexibility. This makes the Pilot H4 BT an excellent choice for R&D de- partments and repair depots to test different battery configurations.
BMS Testing The battery management system (BMS)
is another fundamental component of any battery-powered transportation vehicle, and its correct operation is essential to the per- formance, reliability, and life of the batteries. To ensure that every BMS conforms to
its specification, a comprehensive functional test is mandatory, requiring the capability to simulate the real operating conditions that the BMS is designed to manage. Of course a functional test could involve
the use of all the actual cells in a battery. However, besides the practical difficulties re- lated to the high number of cells, this ap- proach would not ensure repetitive and accu- rate test conditions, and would also lack flex- ibility.
For this reason, the use of battery cell
simulators in the functional test of the BMS is the recommended approach.
Continued on next page
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