E-mobility
Metrological solutions for the future of mobility
Precise measurement technology for e-mobility - from the individual battery cell to the charging infrastructure
Electromobility places the highest demands on metrological components along the entire value chain. Whether in the production of battery cells, the installation of electric vehicles or the quality assurance of the charging infrastructure - precise measuring and testing procedures are essential for safe and efficient electromobility. burster offers powerful measurement technology therefor, which is used reliably in all areas of e-mobility: from motor vehicles, commercial vehicles and industrial trucks to e-bikes.
Incoming goods inspection of battery cells
The quality and performance of lithium-ion batteries is crucial for the range, safety and durability of electric vehicles. Battery cells must be tested for capacity, internal resistance and mechanical stability as early as the incoming goods inspection stage. burster offers high-precision testing and measurement technology to reliably rule out faulty cells in the early production phase of the automation process.
Precision in module production and pack assembly
When assembling battery cells into modules and packs, precise force-displacement monitoring is required to guarantee uniform cell contact and mechanical stability. burster sensors and measuring systems enable seamless monitoring of these processes to ensure the highest quality standards.
Electric motors and power electronics - efficiency and safety through measurement technology
The production of electric motors requires precise testing of windings, magnets and bearings. The power electronics, which control the energy flow between the battery and drive, must also be reliably tested. burster offers solutions for monitoring electrical parameters and for mechanical quality assurance to ensure the efficiency and durability of drive systems.
Safe connection technology in final assembly
In the final installation of electric vehicles, screw and press connections play a decisive role in safety. Battery mounting, high-voltage plug connections and structural screw connections must be examined using precise torque and force measurement systems. burster supplies reliable sensor technology and testing systems for precise installation monitoring therefor.
Charging infrastructure - quality assurance for reliable charging
In addition to vehicle production, the charging infrastructure also plays a central role in electromobility. The quality assurance of chargers and charging columns requires precise measurements of current, voltage, insulation resistance and temperature. burster offers innovative measurement technology for testing and calibrating charging equipment to ensure safe and efficient energy transmission.
Autonomous driving also requires manual handling, such as charging an electric vehicle. When a charging plug is pushed into the charging socket, a low frictional force must first be overcome in order to engage in a defined manner at the end. The Connector must have a high breaking force as a safety criterion, but must also be easy to operate with little manual force.
Solution
The 8524 load cell can be easily integrated into a testing device and displays the necessary frictional, latching and blocking forces in high resolution. With the 9206 USB sensor interface, the sensor's measurement signals can be measured in close proximity and transmitted directly to a PC without the need for an additional amplifier or converter.
- Linearity deviation / linearity error < 0.1 % F.S.
- Overload protection up to 5 times the measuring range
- Measuring range 5 kN
- Measuring ranges from 0 ... 500 N to 0 ... 200 kN
- burster TEDS for more safety
In addition to the high current density per surface area, PRESS-FIT high-current contacts also have the best thermal and mechanical properties. In addition, lower contact resistances are achieved compared to soldering technology. The decisive factor for the quality of the energised contact point is a supported and uniform press-fit process without complete press-fitting onto the assembly. Force/displacement process monitoring is essential for validating this process.
FAQ: How does PRESS-FIT technology work?
Press-fit technology is a solderless connection technique for printed circuit boards in which a contact pin is compressed into the metallised hole (through-hole plating) of a printed circuit board. In most cases, no additional mechanical mounting is required. The counterpart of the electrical connection of the press-fit contact can be, for example, a wrap connection, a blade receptacle, a threaded bolt or a connector (source Wikipedia).
Solution
The manual or automatic press is equipped with force and displacement sensors. Sensors from the burster 8451 and 8552 series are suitable for presses with round slide mounts. The displacement sensor is often used with potentiometric displacement sensors, whereby versions with spring extension or guided driving rod, such as the 8710 or 8712 series, can be used individually depending on the design of the press. The dimensioning of the press and the force sensor should be designed according to the maximum press-in forces of the PRESS-FIT contacts. Ensure that the press-fit zone is equipped with a suitable base, e.g. a mould, to prevent damage to the assembly. The DIGIFORCE® 9307/9311 force/displacement monitoring can validate the quality-relevant parameters of the press-fit phase and especially the end position. Faulty overload situations, e.g. due to pressing up to the block, are recognised by an NOK evaluation and can be ejected. QA-relevant process values are available immediately after pressing and can be read via fieldbus or open communication interfaces.
- Force/displacement process monitoring when press-fitting the PRESS-FIT terminals optimised for manual and automatic presses
- Variable fieldbus and communication interfaces for all PLC and host environments
- Validation of the end position without overload of the assembly/conductor plate
- Optimised for manual and automated processes
A large number of battery cells are required for the production and installation of high-performance battery modules for purely electrically powered vehicles. During input inspection, important battery parameters of each individual cell must be measured and evaluated quickly and reliably within very short cycle times.
Solution
After contacting the prismatic cells, the cascadable battery measuring module measures and evaluates the internal resistance at 1 kHz as well as the cell and module voltage of all 16 cells within approx. 0.5 s and transfers this data to a PLC in real time.
Measuring and evaluation parameters
Ucell ..................... ≈ 0 ... 3.4 to 3.7 VDC
Umodul ................. ≈ 54.4 ... 59.2 VDC
RAC (1 kHz) ......... ≈ 24.91 ... 25.12 mΩ
- Acquisition of internal resistance, voltage of the individual cells and module voltage ≤60 VDC
- Measurement period Internal resistance at 1 kHz as well as cell and module voltage of all 16 cells within approx. 0.5 s
- Up to 5 measuring channels per device. Can be easily cascaded on a top-hat rail due to its small design
- Connection via PROFINET supports flexible sequence control and measurement data acquisition
As an alternative to fixed contact mounting rails and busbars, backplanes with spring contact terminals allow individual testing and replacement of individual battery cells. The dimensional accuracy and spring properties of the contacts are decisive for the quality of such contacts, which is why a 100% check must be carried out for each contact pole.
Special features
- IO/NIO test with high accuracy for force and travel channel
- Acquisition and transfer of the QA parameters spring rate, hysteresis and contact spring base height h0
Solution
Each spring contact is positioned using an automatic X/Y positioning unit on an electric linear actuator with a front-mounted 8431/32 strain gauge force sensor and a test stroke is initiated orthogonally against the spring contact. Depending on the design of the spring contact, only a test stroke of model. < 1 mm compression within the permissible elastic spring deflection.
Although the DIGIFORCE® 9307/9311 process monitoring system can record the quality-relevant parameters basic height h0, spring rate and hysteresis and check compliance with the tolerance specifications. An IO/NIO evaluation and measured values for logging are made available at various interfaces.
- Dynamic recording of force/displacement characteristics incl. IO/NIO monitoring
- Integration into fully automated systems via universal fieldbus interfaces such as PROFINET
- Up to 128 measuring programmes for flexible type management
burster - precision measurement technology for e-mobility solutions
From battery cell testing to charging infrastructure - burster offers a comprehensive portfolio of sensors, measuring systems and testing devices for maximum precision in all manufacturing and testing processes in the field of electromobility. With reliable measurement technology, burster ensures that electric vehicles and their infrastructure comply with the highest quality and safety requirements.
