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Testing Facility for Battery Boxes HSVD

Item 39092

Test system for integration into the production process directly after the injection molding machine
• Product handling by external robots
• Simultaneous testing of 2 test specimen
• Leak test based on a pressure loss test with p <100mbar
• High voltage test for the detection of material defects e.g. at the gates
• Test voltages up to 30,000V DC
• Easy replaceable test adapters
• Optional: touch control panel for parameterization and error display


Standard version
  • High voltage and pressure testing for battery boxes
  • Parallel HV and pressure testing
  • Basic device completely functional
  • With compact controller (Omron NX series)
  • 30kV DC version
  • Without control panel, without size-specific test adapters
Structure of the systemThe system consists of a welded shaped tube frame which contains the switch box, the pneumatic mounting plate and the movable test trolley including 2 holders for test adapters and the pressure cylinders.
  • 1 cover bracket each mounted on the left, right and top directly behind the switch box, for connection to the higher-level protective cladding (symmetrical design of the protective cladding).
  • Control cable to the spraying machine Item no. 28866 (Harting pot housing 32A-gs-M32 with a 16-pin socket insert and a 16-pin plug insert)
  • Switch box centrally mounted, painted in standard color (RAL 7016)
  • U-shaped cover of the pneumatic section made of 6 mm transparent Plexiglas
  • Possibility of locking the test trolley in the open position with a screw
  • Frame painted in standard color (RAL 7016)
FunctionSimultaneous, parallel and independent testing of 2 battery boxes:
  • Easily interchangeable test adapters (2 required per device), if necessary, only one test adapter can be used for testing
  • The device is not designed for manual charging (no protective cover)
  • High-voltage test up to max. 30 kV DC (adjustable via a potentiometer in the switch box)
  • 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 specimensPerformed with 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 molding machine. The contact pressure can be manually adjusted to the battery box size using a pressure reducing valve.
Technical data
  • Maximum dimensions of the battery boxes: L= 508mm x 271mm Height: 206 mm
• Number of chambers per battery box: 6
  • Arrangement of the chambers: See specification of the test adapters
• Net cycle time (insertion completed until removal possible): < 25 s
  • Test time HV: 1 s (adjustable)
• Pressure holding time: 3 s (adjustable)
  • Contact pressure of test specimen: adjustable up to 3,000N at 4.5bar internal pressure
SignalsCommunication with spraying machine:
  • Parallel 24 V PNP signals to terminal strip in the switch box:
Signals to the spraying machine:
  • 1 bit each: Ready for operation, test completed, test specimen inserted,
  • 4-bit signal: Result of the HV/pressure test, specimen 1 / specimen 2
Signals from the spraying machine:
  • 1 bit each: Start, acknowledge fault, dummy mode
  • 4 bits: Perform HV and/or pressure test on specimen 1 and/or specimen 2
  • Emergency stop (2-channel circuit, sets the device to a safe state in the event of an interruption)
Switch boxMounted on the back (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 connectionThe control panel can be plugged into the control unit at any time and is hot pluggable.
Connection boxConnection socket for control panel and "Fault" signal lamp, "Acknowledge fault" button. Connection to the control box of the test device: permanently connected, 7 m connection cable in plastic protective conduit.
DimensionsW= 1,640mm, D=800mm, Hmax=2,341mm
Frame height: 1,700mm, when pressure cylinder is retracted: 2,091mm