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Case Study · Battery Testing

Test bench automation - from zero to productive in 8 weeks

On-site developed test automation for HV battery tests with climate chamber, source/sink and BMS over CAN - including end-to-end sequences, automatic evaluation and audit-proof data storage.

Notice: This video contains AI-generated and AI-edited scenes (EU AI Act transparency).

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 & project scope

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

Automation architecture (the solution)

Process definition

Modular communication and sequence model with safety shutdown, restart logic and clearly defined parameter limits.

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.

System after automation & results

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.

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