Battery Pack Testing and Assembly

MAHLE Powertrain has opened a new facility for the testing and characterisation of cells, modules and battery packs, including 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).

New infrastructure is also being installed to enable the assembly and disassembly of battery modules and 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.

The new facility enables 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 climate controlled test chambers with adjustable temperature and humidity and also incorporates a fire suppression system.

Battery test facility specifications

  • Max battery pack size: 2500 x 1600 x 500 mm
  • Max pack test current: 2400A
  • Max pack test power: 1,000 kW
  • Test temperature range: - 40 to + 90 ┬░C
  • Humidity control: 10% - 95%
  • Fire detection and suppression to BS 5839:2019
  • 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

Battery Pack Testing [PDF; 1778 KB]

MAHLE Powertrain Battery Testing Facility
Battery Development Centre at Northampton, UK