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Case Study · Test Bench Automation

Test bench automation: automate test benches in 8 weeks

Test bench automation for HV battery testing: on-site sequences for climate chamber, source/sink and BMS over CAN — with automatic evaluation and audit-proof data storage.

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Contains AI-generated and AI-edited scenes. Shown for illustration, not raw bench footage.
Reduced test time
60%
Higher fault detection precision
78%
Saved license costs per year
EUR 18,000
To full automation
8 weeks

Initial situation: why automate test benches?

What does test bench automation mean here?

Test bench automation replaces manual operation of climate chamber, source/sink, BMS and logging with reproducible sequences — shorter runtimes, less Excel work and audit-ready evidence for certification paths.

Problem

  • Each component had to be operated manually (climate chamber, source/sink, BMS, logging).
  • No restart after faults or power loss; test runs often started from scratch.
  • Heavy dependence on expensive single licenses of roughly EUR 28,000 per year.
  • Manual Excel-based reporting consumed around two extra hours per run.

Before

MetricValueContext
Test time per run10 hManual setup and evaluation
Reporting per run2 hExcel-based, manually prepared
Active licenses6Multiple single-purpose tools and handoffs

Test bench automation: solution architecture

Process definition

Modular communication and sequence model with safety shutdown, restart logic and clearly defined parameter limits — the foundation to automate test benches reliably.

Device drivers

Custom interfaces for CAN, LIN, Ethernet and RS232 including robust error handling during sequence execution.

Data & reporting

Real-time data logging with automatic limit checks and standardized PDF/CSV reports after each run.

Project timeline

First prototype after four weeks and full automation after eight weeks, including on-site commissioning.

Results after test bench automation

After

MetricValueContext
Test time per run4 hEnd-to-end automation sequences
Reporting per run3 minAuto-reporting in PDF/CSV
Active licenses2Consolidated software stack

Value delivered

  • Decoupling from person-specific know-how through standardized and reproducible test sequences.
  • Audit-proof data storage for traceability and UN38.3-compliant evidence.
  • Immediate SMS and email notifications for faults, limit violations and aborted runs.

FAQ on test bench automation

What is test bench automation for HV battery testing?

It replaces manual operation of climate chamber, source/sink, BMS and logging with reproducible sequences, restart logic, limit checks and auto-reporting — typically over CAN and related device interfaces.

How long does it take to automate test benches?

In this reference project the first prototype was ready after four weeks; full automation including on-site commissioning was productive after eight weeks.

What measurable results does bench automation deliver?

Test time per run from about 10 to 4 hours (−60%), reporting from roughly 2 hours to 3 minutes, consolidated licenses and audit-proof data storage for certification paths.

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