The challenge: comprehensive testing of complex battery packs
Reliable end-of-line testing is essential in the course of series production of 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, leak tests are to ensure that housings and seals meet the requirements. Customers are also demanding the ability 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 integration into existing production lines.
The solution: an integrated end-of-line tester with handling system from Festo
Hahn collaborated with Festo to develop an end-of-line tester that comprehensively tests battery packs immediately after assembly. The system combines electrical tests, mechanical tests, leak tests, and visual inspections.
The handling system from Festo is crucial to the tester’s performance: it positions the tester and cameras so precisely that the test object can be inspected from all sides. At the same time, electrical test sequences are integrated – from overvoltage tests and charging/discharging cycles to 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 hose connectors, continues with valve terminals, and extends to highly complex CNC axes. Everything from a single source, in an integrated system, so that you derive great advantages and synergy effects.”
Martin Sulzbacher, Team Leader R&D, HAHN Automation Group GmbH
Festo as a Seamless Automation Partner
Components, integration, expertise: Numerous Festo components are used in this project. Particularly noteworthy is the handling system, which is supplemented by other standard components such as cylinders, valve islands, and highly complex actuators and CNC axis solutions. This combination provides a consistent system that significantly facilitates integration into the overall plant.
The collaboration between Hahn and Festo is characterized by long-standing trust and close cooperation – from the initial online design to the final dimensioning.
Hahn uses the opportunity to develop initial designs digitally and, in a second step, brings in experts from Festo to carry out the final design of the handling, axes, and actuators. This results in an iterative, efficient development process: Hahn benefits from Festo’s product range and system expertise, as well as from technical support right through to commissioning.
Seamless automation
By combining pneumatic and electrical automation, we offer the broadest portfolio of hardware, software, and AI to meet any industrial motion requirement. Our open system architecture guarantees that individual components will interact in systems from Festo and third-party providers. Our Digital Experience provides support from design and operation to maintenance, throughout the entire length of the project. We complement our technology with a comprehensive learning offering that supports you every step of the way.
That’s the best fit in automation. That’s Seamless Automation from Festo.
Advantages and synergies in practice
The partnership offers several tangible benefits:
- Firstly, the possibility of sourcing components from a single supplier – from simple hose connectors and valve terminals to highly complex drive axles. This reduces interface effort and increases reliability.
- Secondly, integrated systems enable synergy effects in design, procurement, and commissioning.
- Thirdly, Festo offers Hahn training and continuing education solutions: training rooms in Rheinböllen have been equipped with modern learning systems from Festo Didactic, enabling Hahn to invest today in attracting and developing future automation experts.
Hahn Automation
Hahn Automation is a global company specializing in factory automation. Originally with strong roots in the automotive industry, Hahn has diversified in recent years and now also serves 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, which exemplifies how close cooperation with an automation partner accelerates development, integration, and quality assurance.