# FCT Supercapacitors > Source: https://mcd.site team.de/en/industries/automotive-e-mobility/fct-supercapacitors/ > Last updated: 2026-10-05 --- End-of-Line Tester for # Supercapacitors in E-Mobility [Learn More](#) ![](https://mcd.site team.de/wp-content/uploads/2026/07/System_Front_Clean_Spiegelung_2-2-1024x833.png) ## Supercapacitors are high-performance, next-generation energy storage devices. They absorb electrical energy within seconds and release it just as quickly. Especially in modern 48-volt vehicle systems, they enable efficient energy recovery, support the powertrain, and stabilize the vehicle electrical system. Thanks to their high cycle stability, excellent safety, and long service life, they are considered a key technology for the sustainable mobility of tomorrow. ## Challenges and Concept ![](https://mcd.site team.de/wp-content/uploads/2026/07/Adapter_mit_Dut_Wechselsatz_clean-1-scaled.png) ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) Testing 48-volt supercapacitor modules places special demands on test technology, safety, and process stability. Due to the high levels of stored energy and the safety-critical nature of their use in vehicles, all test procedures must be reliable, reproducible, and fully documented. - Electrical functional and assembly testing (FCT) after the soldering process. - End-of-line (EOL) inspection within the automated production line. - Contact and functional tests of the supercapacitor modules. - Controlled two-stage discharge of the energy storage devices before and after the testing process. - Automatic identification of test specimens via UID reading. - Leak and safety tests within the manufacturing cell. - Error and limit value monitoring with configurable test sequences. - Digital recording and traceability of all test results via MES and traceability systems. Among the biggest challenges were the safe handling of high-energy storage devices, the protection of sensitive electronics, and the prevention of operator errors. In addition, a flexible testing technology had to be developed that could be expanded to accommodate future product variants using interchangeable adapters. Intelligent poka-yoke concepts, automatic product recognition, and comprehensive safety features ensure a reliable and error-free inspection process. ## Scope of Testing and Functionality ![](https://mcd.site team.de/wp-content/uploads/2026/07/Wechselsatz_mit_Spiegelung_clean-1024x960.png) ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) The test station we developed combines functional testing and end-of-line testing into a flexible and future-proof overall concept. Here is an overview of the most important test and functional capabilities: - Functional testing (FCT) of assemblies after the soldering process and ICT for testing electronic components and assemblies. - Testing of various product variants using interchangeable adapters on a common test platform. - Automatic product recognition via coded adapters for error-free assignment of the test program. - Two-stage discharge of the supercapacitors: Before the functional test begins, the SCAPs are discharged to ensure reproducible test results. After the test is complete, the SCAPs are discharged again to ensure personal safety. - Safety monitoring during the test procedure through interlocking and protective mechanisms. - Automated end-of-line inspection within the production line, with robot-assisted loading and unloading. - Targeted charging and discharging tests are used to evaluate various characteristics of the SCAP modules. These include: testing the operation of the disconnect switches, checking cell voltages, calibrating the current measurement sensor, measuring capacitance, and measuring ESR (Equivalent Series Resistance). - Reading and processing UID data to ensure full product traceability. - Automatic error detection and test termination in the event of critical deviations or error log entries. - Transfer of all test data to MES and traceability systems for digital documentation and quality assurance. - Error-proofing and reference parts (golden samples) for continuous monitoring of inspection quality. The combination of automated test procedures, integrated safety features, and digital data collection results in a reliable, efficient, and fully traceable testing process for supercapacitor systems. ## Test Methods Used and Results ![](https://mcd.site team.de/wp-content/plugins/elementor/assets/images/placeholder.png) ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30131.svg) Two-stage discharge of the supercapacitors: Before the functional test begins, the SCAPs are discharged to ensure reproducible test results. After the test is complete, the SCAPs are discharged again to ensure personal safety. The testing process includes the automatic identification of test specimens via UID reading, contact and functional tests of the supercapacitor modules, and a controlled two-stage discharge of the energy storage devices before and after the test sequence. Configurable test sequences and continuous threshold monitoring ensure reproducible results. All test data is digitally recorded and fully documented via the integrated MES and traceability systems. A particular challenge was the safe testing of high-current applications with charging currents of up to 20 A and discharging currents of up to 50 A. At the same time, the high levels of energy stored in the supercapacitor had to be safely managed, sensitive electronics protected, and operator errors reliably prevented. Intelligent poka-yoke concepts, automatic product recognition, and a modular design with interchangeable adapters enable a safe, error-free, and future-proof testing process, even for future product variants. # Advantages Over Batteries ![](https://mcd.site team.de/wp-content/uploads/2026/06/Group_30132.svg) **What are the advantages of supercapacitors over batteries?** - Very rapid energy absorption and release - Millions of charge and discharge cycles - Low wear - High power density - Good performance at low temperatures - Reducing the Load on the Vehicle Battery - High level of security and durability This makes supercapacitors particularly well-suited for short-term power demands. Automated handling is provided by feeding, sorting, and transfer systems that ensure a continuous flow of material. Leak testing is performed using high-precision measurement technology, while all test and process data are stored centrally. This ensures a high level of quality assurance, repeatability, and transparency throughout the entire testing process. ## WHAT WE INSPECT ON THE VEHICLE ### SCOPE OF THE AUDIT - Side Door / Door Control Panel - Exhaust / Throttle Area - Cockpit / Center Console - Center console - Heating/HV System - Engine Compartment / Battery Area - Roof / Antenna - Side-view mirrors - Headlights / Front Lights - Tailgate / Lock Area - Windshield / Windshield Wipers ![](https://mcd.site team.de/wp-content/uploads/2026/05/MCD-AUTOMOTIVE_Gemin-2-scaled.webp) ## ECUS FOR LIGHTING CONTROL tested with FCT system - Parallel testing of four PCBs - Manual, semi-automatic or fully automatic adapter - 130 test steps in 95 seconds per test position - Interchangeable needle bed cassettes ## FREQUENTLY ASKED QUESTIONS ### FAQs What are supercapacitors? Supercapacitors (supercaps) are high-performance energy storage devices that can absorb and release electrical energy in a very short amount of time. They are characterized by high power density, long service life, and extreme cycle stability. Why are supercapacitors used in vehicles? They support the recovery of braking energy, stabilize the 48-volt electrical system, and provide short-term high power for safety-critical systems such as steering and braking. What is checked during the functional test (FKT)? As part of the functional testing process, electronic assemblies and components are checked for proper function and electrical properties after the soldering process.v Why do supercapacitors need to be discharged before testing? Since the modules can store large amounts of energy, a controlled discharge is performed before the testing process. This protects operating personnel, testing equipment, and the product. What are the advantages of the automated testing system? The system increases process reliability, reduces operator errors, improves product quality, and enables fully documented and efficient testing of supercapacitor modules. ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp) ## KEY FACTS IN NUMBERS TIMING OF THE TEST PROCESS ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) APPROX. 30 SECONDS FREQUENCY RANGE ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 87.5 kHz (FM) to 2.7 GHz (LTE) VOLTAGE RANGE ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 5 V TO 10 V TRANSMISSION POWER ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 0.001 mW TO 1 mW POWER CONSUMPTION ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 18 mA (GNSS) to 100 mA (FM/DAB) ## downloads [TECHNICAL REPORT](https://mcd.site team.de/wp-content/uploads/2026/07/fachbericht-hf-test-messtec_mcd.pdf) Whether it's radio, navigation, or cellular service, car antennas today receive signals at a wide range of frequencies. Each of these so-called multifunction antennas is tested before shipment. This poses a challenge due to the wide frequency range, reports testing technology specialist MCD. APPLICATION REPORT Learn more directly from the Messtec HF Test application report ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp) ## KEY FACTS IN NUMBERS Structure & Features ### Fully Automated In-Line Inspection System ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### for mechatronic components ### Combination of ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Assembly, Leak Test, and Functional Test ### Two-station system ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Leak-Tightness + Functionality ### Integration of ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### EOL Testing, RWDR Assembly, and Sensor Testing Test Procedures & Test Parameters ### Vacuum and ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Differential Pressure Test ### Angular Accuracy ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### < 0.1° ### Review of ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### ≥ 5 test specimens per variant Flexibility ### Expandable for ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### Various types of sensors and test specimens Quality Assurance & Calibration ### Calibrated Measurement Technology ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### with a tolerance of 2% ### Recommended Calibration Cycle ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) ### 1 year [DOWNLOAD Press Release](https://mcd.site team.de/wp-content/uploads/2026/07/MCD_Elektronik-_Pressebericht_Automatisierung-mit-MCD-Testsystemen.pdf) Learn more directly from the press release DOWNLOAD CASE STUDY Learn more directly from the Messtec HF Test application report ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp) ## KEY FACTS IN NUMBERS TIMING OF THE TEST PROCESS ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) APPROX. 30 SECONDS FCT and end-of-line testing for ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 48V Supercapacitors: Charging Currents Up to 20 A VOLTAGE RANGE ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 5 V TO 10 V TRANSMISSION POWER ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 0.001 mW TO 1 mW POWER CONSUMPTION ![](https://mcd.site team.de/wp-content/uploads/2026/05/Group-2147226339.svg) 18 mA (GNSS) to 100 mA (FM/DAB) ## downloads [TECHNICAL REPORT](https://mcd.site team.de/wp-content/uploads/2026/07/fachbericht-hf-test-messtec_mcd.pdf) Whether it’s radio, navigation, or cellular service, car antennas today receive signals at a wide range of frequencies. Each of these so-called multifunction antennas is tested before shipment. This poses a challenge due to the wide frequency range, reports testing technology specialist MCD. APPLICATION REPORT Learn more directly from the HF-Test Messtec case study ## REFERENCE PROJECTS [![](https://mcd.site team.de/wp-content/uploads/2026/07/1_BMS_Gesamtsystem_frontclean_1-scaled.png)](https://mcd.site team.de/en/industries/automotive-e-mobility/eolt-battery-management-system/) EOLT Battery Management Systems [![](https://mcd.site team.de/wp-content/uploads/2026/07/2_EOL-Tester-Standalone_frei-inklSpiegelung-826x1024.png)](https://mcd.site team.de/industries/automotive-e-mobility/eolt-hochvariable-aussenspiegel/) EOLT Highly Adjustable Exterior Mirrors [![](https://mcd.site team.de/wp-content/uploads/2026/07/eolt-multifunktionsantennen_gesamt-1-1024x839.png)](https://mcd.site team.de/industries/automotive-e-mobility/eolt-fuer-multifunktionsantennen/) EOLT Multifunction Antennas ![](https://mcd.site team.de/wp-content/uploads/2026/05/Multiple-Layers-1.webp)