Markus Zacherl
Head of Sales

telefon +49 3601 4777-145
markus.zacherl@berghof.com

ESPT platform – energy storage testing technology

ESPT - energy storage inspection technology

Battery → Test → OK Ready for integration

 

Alongside the electric motor, the high-voltage storage unit is one of the key components of the electric vehicle. Ultimately, the performance and service life determine the range and fun of driving.

Battery technology requirements are evaluated based on the parameters of energy and power density, lifetime, cost, environmental impact and safety. Berghof Automation specializes in reliable and effective battery testing technology in the field of high-voltage storage.

Energy storage testing technology at a glance

Convincing advantages of ESPT

  • Easy operation: safe and intuitive operation of the test system

  • Flexible software: high flexibility through open, modular test software such as the industry standard LabVIEW

  • Consistent process safety: strict compliance with the necessary safety requirements, especially when dealing with high voltage

  • Comprehensive service and convenient maintenance as well as easy calibration of the entire system

Economical and intelligent technology

  • Future-proof, expandable testing solution

  • Consistent approach of all switching states of the battery

  • Complete verification of all functional and safety-relevant properties

  • Flexible configuration of new test sequences

  • Secure storage of test runs in a separate database

  • Process-safe communication with assembly and conveyor technology

ESPT in the field of production

The future-proof and reliable solution

 

HV storage systems have to meet increasingly stringent requirements. They are therefore becoming more and more powerful, whether through higher capacities, higher charging voltages or currents. We can also test this new technology thanks to appropriate source-sink systems.

ESPT reliably records and evaluates measured variables so that they can be reproduced at any time and are available for any necessary warranty claims between you and your OEMs.

The system accurately logs safety-related data. This data can be transferred to various database systems. The simple and safe operation of the test system guarantees the safety of the workers and prevents possible sources of error in fully or semi-automatic test sequences.

  • Testing of high voltage packages and modules inline and end of line

  • Testing of battery management systems (BMS) for functionality and safety

  • Recording of dynamic voltage/current and impedance measurements

  • Perform insulation and high voltage tests

  • Load test in the form of charge-discharge pulses with high currents

  • Performs leak tests and tests the cooling system

ESPT-P: System layout

  • Control and regulation of the test sequence from the control station

  • Communication of control station and control technology with the source-sink system and the test specimen

  • Communication with company network and internal database systems

  • Communication via all common bus interfaces (Modbus, TCP/IP, VNC, CAN, etc.)

  • Remote maintenance via VPN (NetOp)

  • Integration and creation of various PLC applications

  • Creation of the test software in LabVIEW

  • Adaptation of the test software and the test sequence via the integrated test run editor

  • Load and charge the high-voltage storage devices under test via a regenerative source-sink system

  • Integration of the leak test system possible

  • Insulation monitor that can be switched off

  • Integrated high-voltage measuring system

  • Real-time capable measuring system with numerous communication options to the test object

  • Intelligent residual bus simulation in hardware and software

Our success does not come by chance

When installing a testing system, we incorporate many years of project experience, comprehensive know-how and well thought-out project management to offer a complete solution.

  • Creation of the system layout

  • Design and construction of the protective chamber

  • Preparation of the detailed specification on the performance and scope of delivery

  • Adaptation of the testing software based on LabVIEW

  • Integration of the test system into your data communication

  • Integration of PLC communication blocks for communication between test PC and station PLC

  • Integration of the protection chambers into the control software

  • Adaptation of the operating software (HMI) to the required measurement tasks

  • Supply of all hardware components such as source-sink systems, measurement technology, control technology, protection chambers

  • Delivery of all required HV and LV cables as well as all other adapters

  • Connection of the system to the smoke extraction line

  • Pre-acceptance of the QA system and measurement technology

  • Installation of remote access via VPN (NetOP) to a provided Blue PC

  • Installation of the emergency jettison for the case of average

  • Provision of the CAN-FD interface and the Ethernet from NI

  • Development of a safety concept within the universal test bench

  • Development of a concept for the setting master (optional)

  • Integration of a HV test device from Schleich (optional)

ESPT in the field of quality

Our recipe for success: Quality assurance

In the area of quality, the system from Berghof Automation takes on tasks in the testing of prototypes of batteries/packs as well as modules/cells. These are highly complex test tasks with DUTs that are still in the development stage. In addition, the battery test system is used for audits in quality monitoring. In doing so, our system covers a high variance of test specimens.

  • Test bench management system

  • Integration of air conditioning and conditioning systems

  • Simulates driving profiles

  • Easily customizable test steps

  • Safety, quality, development

  • Real time communication

ESPT for the mobile application

Mobile test systems – for greater flexibility

 

The mobile test box for functional testing of batteries in the low-voltage range is used by our customers in the assembly of battery packs and high-voltage storage systems. It is usually installed on an industrial truck and is supplied via it.

A central unit supplies the box with test parameters, flash containers, etc. The box is contacted to the battery via the low-voltage connection (communication cable to the battery), which automatically starts the test program. The system sends the measured values to the central station, so that they are stored in the quality system of our customers.

Mobile test box – Desktop

The mobile test box is the optimal helper when transport distances have to be covered for testing.

 

  • Testing the functional safety of batteries

  • Independent execution of tests

  • Integration of tests into the production process

  • Testing during the change of station (on the transport routes)

  • WLAN integrated

Mobile test box – Roll container

In addition to the handy test box, ESPT-M is also available as a mobile roll container.

The mobile test box can be flexibly used in production in a roll container.

Mobile test box – Flash Trailer

In the past, the software on the battery control unit was only checked at the end-of-line (EOL) of production - after it had already been installed in the battery.

Now, the Flash Trailer enables an early check before installation.

Proven in practice at BMW and other automotive pioneers.

Discover the future of battery ECU testing!

ESPT in the field of innovation

Every thought and every idea can be the beginning of something really big.

 

In the ESPT-I area, Berghof's developers and engineers deal with the latest technologies and challenges that this future market brings.

All the innovations that have been created have been incorporated into our three areas ESPT-P, ESPT-Q and ESPT-M in order to not only keep our solutions at the cutting edge of technology, but to always be a step ahead.

Hydrogen-based electric drives

In addition to a wide range of other areas, hydrogen-based electric drives, for example, are a focus topic:

In the future, EOL test benches for hydrogen fuel cells are to be developed, which, depending on the customer's individual requirements, will automatically implement complex test sequences.

These will, for example, enable load, safety and communication tests, but will also be able to map leak tests and conditioning processes.

Polytetrafluoroethylene (PTFE) for high voltage and insulation testing

Another area is insulation testing of painted components, especially battery cells or housings for battery modules and battery packs.

This technology is surface contact testing technology using polytetrafluoroethylene (PTFE) for high voltage and insulation testing.

The aim is to avoid insulation faults in the first phase of production. The heart of the system is a construction made of conductive PTFE foil, which we mount so that it can be moved by means of highly elastic foam. To test the safety-relevant arrangement of the coating layer, the device is pressed onto the test specimen and several thousand volts are applied to the film.

If the insulation is faulty, this is precisely detected. The special feature of the technology patented by Berghof is that this special material is highly resistant to electric breakdown.