A leading battery company approached DMC for help developing a custom automated test system for their new BMS PCB manufacturing line. DMC expediently engaged with the client to design and develop a solution based on DMC’s proven Battery Production Test platform. Unique client requirements required adding cell simulation functionality, software flash/programming, and PCB validation tests to DMC's BPT standard platform.
Test Specification
The functional test specification required:
- BMS firmware flashing
- Cell emulation
- Thermistor emulation
- Temperature and voltage tests
- Communication over CAN and serial buses
- Analyzing LED status indicators
Each BMS test resulted in a report with metadata identifying the DUT, test system configuration, and test results with limits included.
Systems Engineering
DMC had to factor in many requirements including test accuracy, cycle time, operator ergonomics, and overall system envelope. DMC leveraged our internal fabrication shop and carefully selected external vendors like Pickering for robust hardware solutions. The software design leaned on DMC’s existing platforms and tools to minimize costs while maintaining performance and reliability.
DMC divided the hardware design into modular sub-systems: data acquisition box, Bed-of-Nails test fixture, and instrument rack. The rack design housed multiple Pickering LXI chassis containing cell simulation and thermistor cards. The interfaces between these sub-systems were well defined early in the design process, along with consistent communication to minimize design siloing.
Software Design
Software customizability was a major consideration for the client, DMC built upon its proven Battery Production Test (BPT) platform to meet client's software requirements. Some highlights include:
Conclusion
DMC delivered a robust and highly configurable system on a deadline, providing our client with BMS test capability ahead of their full battery pack assembly line. The solution detects manufacturing defects and provides traceable test results to each battery under test.
Learn more about DMC's Battery Production Test (BPT) System, check out this BMS Power HiL Test System, or contact us to discuss your next project.