Fully charged for successful battery test

MK Test Systems and IONIO brings their Automeg® automated testing systems to the battery sector.

The Automeg® product range has been used for more than 30 years in demanding industries such as aerospace, defence, and rolling stock manufacturing and maintenance. The systems have earned a reputation for ensuring the integrity and performance of electrical and power distribution systems.

The world’s leading plants for electric trucks and buses are increasingly using Automeg, including Daimler Truck North America. These systems typically offer HV testing up to 6000VDC and high voltage dielectric test (HiPot) up to 3500VAC, and benefit from MK’s years of experience in testing rolling stock where similar voltages are common.

A recent application at an electric truck used MK’s loop test technology, which automatically tests the bond resistance of earth circuits on a chassis for total resistance. It then measures the current flowing through each part of the network of parallel circuits to allow detection of high resistance connections. These high resistance connections can eventually lead to hotspots and compromise vehicle safety. See our DTNA case study for more details.

Battery test requirements
In EV battery testing, many standard features of the MK Automeg test system are used for:

– Earth connection test with variable programmable currentrn- Measurement and verification of pack connection and weldingrn- Resistance measurement of terminalsrn- Capacitance measurement of terminalsrn- Measurement and switching of high currentrn- Insulation test with high voltage and controlled fast dischargern- High-voltage dielectric resistance test (HiPot) and controlled rapid dischargern- Functional test of internal pack contacts and relaysrn- Functional test of high-voltage interlocksrn- Resistance measurement and verification of fuse paths

After the range of standard MK test modules is selected and built into a test console, the MKAT® software is used to create specific test sequences to suit a particular battery cell. As new battery cells are developed, the user easily creates a new test sequence to suit that cell.

At the touch of a button, the test process is started as soon as the system is connected to the battery cell. Test results are delivered in a report format and are automatically logged and archived. Digital archiving ensures full traceability and enables trend analysis. In this way, Automeg and MKAT support continuous product and process improvement, as well as IoT and Factory 4.0 goals.

Standard capabilities of the MK Automeg system include accurate continuous resistance measurement, low-voltage insulation testing, high-voltage insulation measurement, high-voltage AC HiPot testing, high-current switching and measurement, and function test stimulation. All these functions are routed through a series of relay modules, providing fully automatic measurement of high-density circuits.