End-of-Line Testing of Preh’s Battery Management Systems

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Preh Group, a global leader in automotive electronics and e-mobility solutions, has been driving innovation since its founding in 1919. Headquartered in Germany, the company specializes in cutting-edge vehicle control systems and electric mobility technologies. Preh partners with leading automotive manufacturers worldwide. With production and development facilities across the globe, the company delivers customized solutions that meet the evolving needs of the industry.

Optimizing Electric Vehicle Performance with Advanced Battery Management Systems

As electric vehicles continue to gain momentum, effective battery management is critical for optimizing performance, safety, and longevity. Preh’s Battery Management Systems tackle key challenges like temperature fluctuations and voltage instability, which can shorten battery life. These high-voltage BMS solutions deliver precise monitoring of individual battery cells, ensuring efficient charging and reliable operation even in demanding conditions.

Designing a High-Precision Testing System for High-Voltage BMS

Engineers at Preh’s Trofa plant near Porto, Portugal, faced the challenge of developing a new end-of-line testing system for their high-voltage BMS production line. The solution needed to provide exceptional precision, reliability, and seamless integration with both existing test system architectures and future EtherCAT-based systems. To meet these requirements, Preh partnered with PerfectDecibel, a renowned data acquisition consultancy, and Gantner Instruments, a trusted leader in high-voltage automotive testing solutions.

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Data Acquisition System Overview

The EOL testing system incorporates Gantner Instruments’ advanced data acquisition modules to achieve unparalleled measurement accuracy:

Voltage Measurement:

• Q.bloxx XL A123 SEB: Measures low voltages between two points in a high-voltage circuit.
• Q.bloxx XL A127 2CV: Provides direct measurement of high voltages, suitable for EV components operating at 400 or 800 VDC.

Current Measurement:

• Q.bloxx XL A127 2CV: Combined with a LEM LF 2005-S current transducer, the system delivers highly accurate current measurements.

Safety Features:

• All measurement inputs feature high-voltage sockets with continuous galvanic isolation up to 1200 VDC. This ensures user safety and protects devices from transient high-voltage spikes, in compliance with IEC 61010-2-030 standards (CAT II 1000V and CAT III 600V).

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Intelligent DAQ Control with Q.station X

The Q.station X controller is the central component of the DAQ system, responsible for managing real-time data acquisition and precise time synchronization. Its advanced features include:

• Multifrequency Data Processing: Facilitates high-speed data streaming with minimal overhead.
• Comprehensive Fieldbus Support: Interfaces seamlessly with CAN, Modbus TCP, Profinet, and EtherCAT.
• Flexible Communication: Offers a platform-independent software interface with a free API for easy access to measurement data.

By leveraging Gantner Instruments’ data acquisition technology, Preh has successfully developed a robust, high-precision end-of-line testing system for its high-voltage BMS production lines. The modular design and versatile connectivity of Gantner Instruments’ DAQ systems enabled seamless integration into Preh’s existing testing framework. Additionally, the system’s EtherCAT slave interface ensures readiness for next-generation test system designs, eliminating the need for further hardware investments. This collaboration enhances Preh’s ability to ensure product quality and safety in the rapidly evolving e-mobility industry.