FCT Systems

Reliable testing technology for Battery Management Systems

High volumes, short cycle times and maximum process reliability.

Series testing of battery management systems places high demands on both people and technology. MCD Elektronik developed a solution using a modular end-of-line test system that combines parallel test sequences, safe high-current contacting and complete traceability. This creates efficient and reproducible test processes for automotive production.
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Challenges and Concept

In addition to reliably testing safety-related functions, the test system must provide reproducible, low-resistance high-current connections. It must also achieve short cycle times for series production.

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Blinker, Kamera, Heizung und Assistenzsysteme.

FCT Systems

Außenspiegel

Reliable testing technology for Battery Management Systems

Modular EOL test system for battery management systems

For this application, MCD Elektronik implemented a modular VTS 2030-based test system with two test nests and interchangeable adapters for testing two assemblies in parallel. Integration with traceability systems documents all test results.

System voltage
12 V
Parallel testing
2 assemblies
Current matching
Up to 200 A

Ein flexibler End-of-Line-Prüfstand

MCD entwickelte hierfür einen flexiblen End-of-Line-Prüfstand, der sämtliche Varianten innerhalb von weniger als 30 Sekunden prüft. Das System kombiniert optische, mechanische und elektrische Prüfverfahren zu einem durchgängigen Prüfkonzept.

Produktvarianten

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Produktvarianten

Über 30

Taktzeit pro Bauteil
Taktzeit pro Bauteil
Unter 30 s

Qualitätskontrolle vor Auslieferung

Qualitätskontrolle vor Auslieferung

100 %

Scope of Testing and Functionality

The EOL test system checks the relevant electrical and communication functions of the battery management system and combines these with secure high-current connections, automatic identification, and process monitoring:

BMS test adapter with two test nests
Front view of the test fixture
Modular interchangeable adapter
EOL test system for battery management systems
Overall view of the test system
Modular system design
Test fixture for battery management systems
Close-up of the test fixture
Adapter and contacting technology

Current, voltage and temperature measurements, along with key BMS operating functions, are tested automatically.

  • Current, voltage and temperature measurement
  • Quiescent current measurement
  • Sleep mode function testing
  • Voltage drop measurement across the power path

Test units are identified automatically, and the BMS communication interfaces are tested specifically.

  • Barcode/Data Matrix code scanning
  • Communication testing via CAN-FD
  • Communication testing via LIN
  • Automatic PASS/FAIL evaluation

Low-resistance high-current contacting enables safe testing and calibration of the power path under defined conditions.

  • Reliable high-current contacting
  • Calibration of power measurement and the shunt resistor
  • Current matching up to 200 A
  • Verification of measurement accuracy in the power path

Guided processes, traceability and parallel testing support a reliable, high-availability production process.

  • Parallel testing of two assemblies
  • Graphical operator guidance
  • Traceability and database integration
  • Designed for 24/7 series production
Bauteilaufnahme im EOL-Prüfstand
Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

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Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

Kamerasysteme kontrollieren Lichtfunktionen und Spiegelstellungen, während Antriebe, Klappmechanismen und elektrische Funktionen automatisiert getestet werden.

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Kamerafunktion

Länderspezifische Varianten

Auch das Nicht­vorhandene zählt.

Die Negativprüfung stellt sicher, dass sich nicht verbaute Ausstattungsmerkmale nicht aktivieren lassen. Geprüft wird auch, was fehlen muss.

mcd_plus_white
High test throughput with reliable process control

Two test nests enable parallel testing of assemblies. Guided handling, defined process sequences and automatic product identification reduce operator errors and support short cycle times while maintaining high test quality.

Test Methods Used and Challenges

End-of-line testing of 12 V battery management systems combines electrical measurements, communication testing, cell simulation and high-current tests with complete digital traceability.

Identification and communication
Automatic identification via barcode or QR code scan
Communication testing via CAN-FD and LIN
Automatic PASS/FAIL evaluation
Digital storage of test data
Electrical BMS testing
Current, voltage and temperature testing under simulated operating conditions
Functional testing of sleep mode and other BMS functions
Cell simulation using a project-specific MCD PCB
Voltage drop measurement across the power path
High-current and calibration testing
Safe high-current contacting and connector testing
Power path and shunt resistor adjustment up to 200 A
Simulated charging and discharging currents from 3 A ± 0.003 A to 150 A ± 0.075 A
Verification of measurement accuracy in the power path
Process and quality assurance
Parallel testing of two assemblies to optimize cycle time
Integration with traceability and database systems
Modular design with interchangeable adapters
Intuitive operator guidance for a reliable test process
Funktions- und Qualitätsbewertung
Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

Optische Prüfungen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Kamerabasierte Erkennung von Lichtfunktionen

Analyse von Spiegelstellungen

Kontrolle des Spiegelglases

Mechanische und elektrische Prüfungen

Antriebe und Klappmechanismen werden mechanisch geprüft, während Winkelpositionen bestimmt sowie Spannung und Stromaufnahme gemessen werden.

Bewegungsprüfung der Antriebe

Winkelmessung der Klappfunktion

Stromaufnahme der Motoren

Funktions- und Qualitätsbewertung
Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

FREQUENTLY ASKED QUESTIONS

FAQS

A BMS in a motor vehicle monitors and evaluates battery parameters such as cell voltage, temperature, and current. It protects the battery from overcharging, deep discharge, overcurrent, and overheating, and contributes significantly to the safety and service life of the battery system. In addition, high-voltage batteries in automobiles are controlled, ensuring continuous operation within defined limits.
Among other things, current and voltage measurements are performed, temperatures are recorded, and the sleep mode, communication interfaces (such as CAN-FD and LIN), safety-related functions, and high-current contacts are tested.
The end-of-line test ensures that every BMS assembly produced functions in accordance with specifications immediately after manufacturing. This allows manufacturing defects to be detected early, prevents defective assemblies from being shipped to customers, and thus prevents vehicle malfunctions that could result in dangerously high current loads.
All measurement and test data are automatically captured and stored in a database. Serial numbers, timestamps and test results for each individual BMS can therefore be fully traced.
Yes. The test system we developed enables two BMS assemblies to be tested in parallel using the MCD TestManager software tool. This reduces cycle times and increases throughput in series production.

KEY FACTS

Key facts at a glance

Test system
End-of-line test system
Handling
Semi-automatic
Concept
Multi-purpose single test station
– 2 DUTs per test sequence
Test methods & scope
Electrical: voltage, current
Temperature testing: temperature
Components
MCD TestManager, project-specific PCB for cell and temperature simulation, MCD Toolmonitors, VTS 2030 rack system, MCD controller MIO1616, multiplexer, barcode scanner

REFERENZPROJEKTE

EOLT Systems

Multifunction Antennas

FCT Systems

Supercapacitors in E-Mobility

EOLT Systems

Exterior Mirror