Control Sistem designs and manufactures test benches for the characterization, diagnosis and qualification of high voltage (HV) batteries. Examples of such applications lie in batteries reconditioning lines, which are composed of a series of workstations that involve most of the tests that can be performed on the vehicle batteries.

Test stations typically consist of the following elements:

• Main Automation Electrical Panel
• Break Out Box for power connections with the battery
• Power panel (high-voltage cyclers, controllable in voltage, current, or power)
• Battery cooling circuit conditioning chiller

The automation panel incorporates the electronics necessary for interfacing with the battery BMS (CAN communication, CAN, CAN UDS, etc.), as well as sensors to acquire test nodal data (current sensors) and the safety elements necessary to safeguard the proper functioning of the components and the battery in the event of malfunctions (e.g., electronics to identify the loss of pole-to-ground insulation, decoupling contactors, etc.). There is a Panel PC, on which the software application operates allowing you to define the communication with the battery, management of operational tests, data storage, display of graphs in real time, alarm management, etc.

The Break Out Box is the element that conveys the "+" and "-" poles of the test bench to the battery power connection point(s). A single Break Out Box can connect multiple power outputs, related to different battery families, also managing any polarity reversals.

The cycler is the element that imposes the set voltage or current on the "+" and "-" poles, depending on the function to be performed (charge, discharge, pulse test, etc.).

The air conditioning chiller has the task of circulating the carrier fluid in the cooling pipes of the coil, in order to maintain a thermostat of the battery modules, as happens on the car; it has the automatic functions of loading and emptying by flushing with compressed air (blow out).

Using these elements, a test station is therefore complete and capable of carrying out any type of test on high-voltage (HV) batteries.