Modular high-voltage test systems guarantee flexibility

by Silke Thole

Lithium battery pack in the engine compartment of an electric car. Image: Sergii Chernov /
Lithium battery pack in the engine compartment of an electric car.
Image: Sergii Chernov /
In the current eMobility boom, manufacturers of battery systems face the challenge of bringing products to market quickly without knowing the future trends and quantities required. This is where the measurement and test system specialist SMART TESTSOLUTIONS helps with its modular development approach. The results are testers for battery systems that can be converted to other DUTs than those initially intended without fundamental modifications. Only individual modules have to be exchanged.
SMART TESTSOLUTIONS is known in the eMobility environment primarily for its systems for cell voltage monitoring (CVM) of fuel cells. In addition, the Stuttgart-based company develops test systems for other eMobility applications – for example the end-of-line test of complete battery systems. Depending on the customer's requirements, both the company's own high-voltage-capable system modules for recording measured values, load and sensor simulation as well as third-party components are used.
All test systems usually have a modular approach in common: power supply, safety technology and components such as insulation monitors and measuring devices, voltage and current measuring components are accommodated and wired separately from the application module in the test system cabinet. "Defined safety mechanisms ensure that there is no danger to life and limb even in the event of potential operating errors in the test system," emphasizes Norbert Witteczek, responsible for the Test Systems product area at Smart Testsolutions, the special importance of safety in high-voltage applications. "Here we always work closely with our customers and the users".
Finally, the application module houses all functions and circuitry that are dependent on the respective DUT and may need to be modified. The advantage of the modular design becomes apparent if another DUT with a modified test connection is to be tested later: Then it is sufficient to replace this module without having to fundamentally rewire the system. All other components are retained.

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