The Hahn Battery EOLT is a complete solution for testing battery packs. All relevant test scenarios for 90% of all battery packs available on the market can be implemented on the end-of-line test system, as the system is easily scalable to many sizes. From power electronics and test equipment to test software and automation, Hahn Automation offers everything from a single source. "Thanks to its extensive expertise in testing technology, the company helps to define the best testing strategies in order to optimize cycle times and ensure the desired product quality," says Christian Bubat, Global Business Development Manager at Hahn Automation. During development, the company worked together with the "Production Engineering of E-Mobility Components" (PEM) department at RWTH Aachen University.

Play it safe

"A newly developed fire protection and safety concept for the EOLT battery tester ensures reliable detection in the event of a fire," adds Martin Sulzbacher, Head of R&D at Hahn Automation. In such a case, the battery is closed fully automatically to contain the fire and then also transported fully automatically to a safe area. Smoke filters prevent contamination of the surroundings. "Fires in battery factories have sometimes led to two weeks of production downtime, as the halls had to be extensively cleaned and decontaminated due to the toxic fumes," continues Sulzbacher.

But how does a battery test work? "We wouldn't be Hahn Automation if we left no stone unturned to automate every step of the process," continues Bubat. In the first step, a battery pack enters the battery tester with a self-driving AGV. The battery pack is contacted with connectors via a specially developed, standardized coupling, charged and discharged again. A high-voltage test completes the electrical test routine. To test the tightness of a battery pack, it is filled with helium.

A helium sniffer lance for the leak test and a camera for visual inspection are attached to the 3-axis gantry with Festo EGC electric drives. The axes are driven by EMMT-AS motors and controlled by Festo CMMT-AS controllers. This means that the drive and control package is perfectly coordinated.

Precise testing

The axle portal moves and positions these two sensors along all edges of the battery pack to detect any leaks in the housing and the battery cooling system. The camera checks that all labels and stickers are correctly positioned and that the battery pack is in perfect condition and detects any mechanical damage. A test of the battery management system checks the communication and evaluates the sensors.

"As the individual process steps show, we look at battery testing from the perspective of automation. The battery tester combines several tests and could be in operation 24 hours a day in three shifts," explains Bubat. It is therefore important that Hahn Automation can also work with reliable automation partners on the supplier side.

Fast design and simulation

"As in many previous automation projects, Festo has proven to be the right, globally reliable partner in electrical and pneumatic automation technology," adds Head of Development Sulzbacher. The partnership with Festo begins with the design and product selection: "Easy-to-use design and simulation tools make our work easier," he continues. Thanks to the long-standing partnership, the company has been familiar with Festo's automation products for a long time and can use them in a targeted manner. With online product finders, intelligent design software and engineering tools, the design engineers at Hahn Automation can find the right products for the development of new machines and systems reliably, quickly and without time-consuming calculations.