Control Sistem designs and manufactures automated test lines for battery modules, aimed at electrical and functional verification as well as conformity validation for use in automotive and industrial applications. These lines are typically integrated within production cells and operate fully automatically, ensuring high repeatability and traceability of results. The test stations are composed of a combination of hardware and software components capable of performing the following checks:

• CMC information reading: acquisition of module and electrical configuration identification data via test master board.
• Cell voltage measurement: verification of individual cell voltages to identify any anomalies at an early stage.
• Module voltage measurement: control of the total voltage of the module to validate the correct assembly and balance.
• Cell stack measurement: Measurement of partial voltages for series cell segments.
• Module temperature detection: use of PT100/PT1000 sensors for thermal monitoring during the test.
• Electrical insulation test: verification of the insulation resistance between poles and ground using a special instrument.
• Dielectric Strength Test (Hi-Pot): Controlled application of high voltage to ensure the integrity of electrical insulation.
• Internal resistance measurement (DC-IR): Evaluation of internal losses and module health.
• Controlled power supply: Programmed current/voltage delivery for dynamic measurements and testing under conditions di simulated load.

The testing line is supervised by dedicated software, installed on a Panel PC, which manages:

• Communication with the module’s control electronics
• Automatic test sequences
• Real-time signal and alarm monitoring
• Data acquisition and result storage in a database
• Complete traceability via code or serial number reading
• Robot management for module handling

  The entire architecture is based on a master test board capable of managing BMS communication and the analog/digital signals required to perform the tests, integrated with high precision multimeters, current sensors, power supply systems, and insulation verification devices.