The challenge: comprehensive testing of complex battery packs
Reliable end-of-line tests are essential when mass-producing battery packs. The testing requirements are complex: electrical tests such as surge tests, charging and discharging cycles, and communication tests with the battery management system must be covered, as must mechanical and optical tests. In addition, leakage tests must ensure that housings and seals meet the requirements. Customers are also requesting to have the option to flash specific software directly onto the battery modules.
The challenge for Hahn was to combine all these requirements in a modular, scalable testing system with a high degree of integration and easy installation into existing production lines.
The solution: an integrated end-of-line tester with handling system from Festo
Hahn worked together with Festo to develop an end-of-line tester that comprehensively tests battery packs immediately after assembly. The system combines electrical tests, mechanical tests, leakage tests and visual inspections.
The handling system from Festo is crucial to the performance of the tester: it positions the tester and cameras so precisely that the test object can be inspected from all sides. At the same time, electrical test procedures are integrated, including overvoltage tests, charging/discharging cycles as well as communication with the battery management system. In addition, the system allows customer-specific firmware to be imported.
'At Festo, we have the advantage of getting everything from a single source. It starts with simple tubing connectors and valve terminals, and extends to extremely complex CNC axes. Everything comes from a single source, in a continuous system, offering significant advantages and synergy effects.'
Martin Sulzbacher, Team Leader R&D, HAHN Automation Group Ltd.
Festo as a seamless automation partner
Components, integration, expertise: numerous Festo components are used in this project. The handling system is especially remarkable, as it is enhanced by other standard components such as cylinders, valve terminals and highly complex actuators and CNC axis solutions. This combination provides a uniform system that significantly facilitates integration into the overall system.
The collaboration between Hahn and Festo is characterised by complete trust and close, long-standing cooperation, from the initial online design to the final sizing.
Hahn uses the opportunity to develop the initial designs digitally and, in a second step, consults experts from Festo who finalise the design of the handling system, axes and actuators. This results in a consistent, efficient development process: Hahn benefits from the product range and system expertise from Festo, as well as from technical support right through to commissioning.
Seamless Automation
By combining pneumatic and industrial electrical automation, we offer an extremely wide-ranging portfolio of hardware, software and AI to meet every industrial motion requirement. Our open system architecture guarantees that individual components in systems from Festo and third-party suppliers will interact smoothly. Our Digital Experience provides support, from design and operation to maintenance throughout the entire project. We enhance our technology with a comprehensive range of learning opportunities that supports you every step of the way.
That's the best fit in automation. That is Seamless Automation from Festo.
Benefits and synergies in practice
The partnership offers several tangible benefits:
- Firstly, the possibility of purchasing components from a single source, from simple tubing connectors and valve terminals to highly complex drives and axes. This reduces interface effort and increases reliability.
- Secondly, integrated systems provide synergy effects in design, procurement and commissioning.
- Thirdly, Festo also provides Hahn with basic and further training solutions. The raining rooms in Rheinböllen have been equipped with modern learning systems from Festo Didactic, allowing Hahn to invest in attracting and developing future automation experts today.
Hahn Automation
Hahn Automation is a global company specialising in factory automation. Although Hahn was originally firmly rooted in the automotive industry, it has diversified in recent years and is now also active in the consumer goods, medical and electronics sectors. Core competencies are assembly technology and testing technology, preferably in modular concepts that can be flexibly adapted to customer-specific requirements. One of the latest developments is an end-of-line tester for battery systems that shows how close cooperation with an automation partner accelerates development, integration and quality assurance.