Battery Pack Assembly and Testing

MAHLE Powertrain has built a new facility for the assembly and disassembly of battery modules and small battery packs. This will allow the strip and inspection of post-test modules and units from field-trials in addition to assembly of new prototype units. .

New infrastructure is also being installed to enable the testing and characterisation of cells, modules and battery packs. Steady state testing of open circuit voltage, storage capacity and thermal characterisation tests (e.g. voltage response under high discharge, thermal behaviour and internal resistance).

The new facility will also enable testing under drive-cycle conditions to help evaluate the performance of battery systems in the context of real driving behaviour and extreme testing conditions.

The facility can be used to test packs and modules with and without battery management systems. It is modular in design to enable fast, cost effective expansion to support increases in customer demand. The new test facility houses a climate controlled test chamber with adjustable temperature and humidity and also incorporates a fire and suppression system.

Battery test facility specifications

  • - 40 to + 100 °C
  • Humidity control
  • EUCAR 5 fire detection and suppression
  • Remote chamber control
  • Bi-directional power supply for module testing with cycling control software and control of environmental chamber
  • Dynamic test cycles possible as well as steady state characterisation
MAHLE Powertrain Battery Testing Facility