Testing Facility for Battery Boxes HSVD

High voltage and pressure testing for battery boxes
Parallel HV and pressure testing
Basic device fully functional, with compact control
Version 30kV DC
without control panel, without size-specific test adapters

The device corresponds to the devices already supplied to Clarios in Ceska Lipa, supplemented by

• 1 cover bracket each mounted on the left, right and top directly behind the switch box, painted in RAL 1018 (zinc yellow), for connection to the protective panelling (symmetrical design of the protective panelling). The width of the cover angles was adjusted - the side cover angles were each narrowed by 20 mm, the width of the upper cover angle was shortened from 1000 mm to 960 mm.
• Control cable to the spraying machine our article no. 28866
• Control box not offset to the left, painted in standard colour
• U-shaped cover of the pneumatic part made of 6mm transparent Plexiglas
• Possibility of locking the test trolley in the open position with screw
• Frame painted in standard colour

[ Function ]
Simultaneous, parallel and independent testing of 2 battery boxes

• Easily interchangeable test adapters ( 2 required per device ), if required, testing can only be carried out with one test adapter
• The device is not designed for manual charging (no protective panelling) - it must be integrated into an appropriate safety area at the connection points provided (mechanical and electrical)
• High voltage test up to max. 30 kV DC
• Pressure test for pressure loss at approx. 40 mbar ( pressure adjustable ), adjustable pressure holding time ( test time ), adjustable permissible pressure loss during the pressure holding time

[ Inserting the test specimens ]
Is carried out using an external robot. Test specimens are placed on the test adapter from above.
The test trolley with the installed test adapter moves into the test position. The locking cylinders press the battery boxes onto the test adapter with reduced pressure.
The correctly pressed-in battery boxes are checked by passing the lower limit switch of the locking cylinder. When the lower limit switch is passed, the system switches to the contact pressure.
After the test, the clamping cylinders open, the test carriage moves back into the insertion position and the test specimens can be removed by the robot.
The results are transferred to the injection moulding machine.
The contact pressure can be manually adjusted to the battery box size using a pressure reducing valve.

[ Communication with injection moulding machine ]
Parallel 24 V PNP signals to terminal strip in switch box:
Signals to injection moulding machine:

• 1 bit each: Ready for operation, test completed, test specimen inserted,
• 4-bit signal: Result of test HV/pressure, test specimen 1 / test specimen 2

Signals from injection moulding machine:

• 1 bit each: Start, acknowledge fault, dummy mode
• 4 bits: Perform HV and/or pressure test on test item 1 and/or test item 2
• Emergency stop ( 2-channel circuit, sets the device to a safe state in the event of an interruption )

[ Maximum dimensions of the battery boxes ]

• L= 508mm x 271mm Height: 206 mm

Total number of chambers per battery box: 6
Arrangement of the chambers:

• See test adapter specification

Net cycle time ( insertion completed until removal possible ): < 25 s
Test time HV: 1 s ( adjustable )
Pressure holding time: 3 s ( adjustable )

[ Contact pressure test specimen ]

• adjustable up to 3,000N at 4.5bar internal pressure

[ Switch case ]
Mounted on the rear ( narrow side ) of the appliance. Operating elements on the door: Main switch, high voltage off ( service switch ), pressure regulator with pressure gauge for setting the contact pressure

[ Control panel connection ]
The control panel can be connected to the control unit at any time and is hot pluggable.

[ Connection box ]
Connection socket for control panel and ‘Fault’ signal lamp, ‘Acknowledge fault’ button.
Connection to the control box of the test device: permanently connected, 7m connection cable in plastic protective conduit.

[ Dimensions ]
L= 1,640mm, W=800mm, Hmax=2,341mm
Frame height: 1,700mm, when pressure cylinder is retracted: 2,091mm