Modular Test System MTS

Baumann's Modular Test System (MTS) is a scalable test platform for the safe testing, diagnosis and further processing of high-voltage batteries and power electronic assemblies. The system combines electrical testing, safe high-voltage contacting and controlled charging and discharging in a modular architecture.

With its flexible design, the MTS is suitable for development applications, validation, series testing, and processes in the areas of second life, pre-treatment, and end of life.

Modular system for flexible testing processes

The MTS is based on a modular system concept. Individual function modules can be flexibly combined and adapted to different DUTs, voltage ranges and safety requirements.

Standardised interfaces, separate control architectures and a scalable hardware structure enable high system availability and long-term investment security. The system grows with new product generations and changing market requirements.

Safe high-voltage, low-voltage and FPC contacting as the basis for testing

A stable and secure electrical connection is the basis of every high-voltage test. Within the MTS, the Modular Contacting System (MCS) handles the precise contacting of high-voltage, low-voltage and FPC applications. 

The MTS/MCS enables the processing of voltages up to 5000 V and currents up to 500 A as standard and ensures maximum process reliability in battery and e-mobility applications thanks to integrated safety mechanisms. Individual adjustment of voltage and current limits is possible at any time on request.

Entladetechnik für Recycling, Second-Life-Prozesse und sicheren Transport

In addition to diagnosis and testing, the MTS also integrates the controlled discharge of high-voltage batteries. The discharge technology for high-voltage batteries enables safe discharge to 0 volts prior to recycling or pre-treatment processes. 

The MTS thus supports not only classic testing tasks, but also applications in the areas of battery reconditioning, second life, end of life and safe transport.

Comprehensive process from diagnosis to end of life

Das Modular Test System bildet eine durchgängige Prozesskette für

• Diagnosis and condition assessment of high-voltage batteries

• Second-life assessment and reuse

• Pre-treatment before recycling

• Controlled discharge

• End-of-life processes

All modules are synchronised and enable reproducible, secure and scalable processes within a uniform system platform.

Your advantages with the Modular Test System

• Modular and scalable test architecture

• Test software that can be configured and programmed freely by the user
• Integration of high-voltage and high-current contacting and discharge technology
• High process reliability for all applications
• Flexible adaptation to different battery types and designs
• Can be automated up to robot-assisted processes
• Future-proof platform for e-mobility, recycling and Industry 4.0

Exemplary selection of test cases:

• Checking the software status of the test object
• Evaluating fault memory entries
• Measuring the insulation resistance of the battery and testing the electrical strength
• Measuring the Y capacity
• Checking the internal voltage measurement for plausibility
• Measuring the current consumption of the battery
• Interlock function test
• Internal temperature measurement
• Current pulse test
• Checking the state of charge
• and much more.

Advantages of the test framework:

• User-customizable test recipes and test sequences
• Intuitive graphical user interface and a wide range of graphical diagnostic and analysis functions
• Integration of special functions (e.g. flashing, authentication, etc.)
• Standardised data interfaces to production and customer systems (MES systems)
• Process monitoring of DUT and test system during testing
• Communication with DUT via all common bus systems in the automotive sector (CAN, LIN, Automotive Ethernet)
• Open data storage in the form of JSON or XML data

Baumann MTS Units:

• CCU - Control & Communication Unit
• MDU - Measurement Distribution Unit
• HVDU - High Voltage Distribution Unit
• HCDU - High Current Distribution Unit
• HCMU - High Current Matrix Unit
• CMU - Communication Matrix Unit
• PDU - Power Distribution Unit