OEMs and battery suppliers have to continuously develop new packs for the evolving automotive market. For battery electric vehicles (BEVs), the mileage range is a key factor, making the capacity of battery cells and packs crucial. In addition to capacity, current and voltage are central to battery development. As a result, the test systems for validating battery packs need to be state-of-the-art.
Our AVL solution measures all important parameters under different environmental conditions. Further, it is equipped with multifunctional interfaces connecting to additional tools necessary for battery testing. AVL has a closed toolchain in hardware and software for every possible need during battery development. The combination of development services for the customer and the independent development of test equipment provides AVL with a holistic view of the challenges faced in the domain of battery testing.
We offer a complete battery testing performance portfolio including cell, module and pack solutions. Every system is communicating via CAN and protocols like EtherCAT are already implemented. In addition, we supply full facility design and development. Due to the high level of expertise and internal collaboration within the AVL Simulation and Engineering departments, test equipment is developed fitting every need of battery manufacturers and OEMs.
Thanks to our optimized hardware and software toolchain, the whole product life cycle can be supported. Moreover, the interaction between all electrification system departments like battery, e-motor, e-drive, and fuel cell make the implementation of full support possible. Unified battery models for emulation are used to apply realistic battery behavior on electrification testbeds. In addition, we offer properly approved safety components according to ISO 14120.The main task of the safety system is to control and monitor the safety equipment of the testbed and to reduce the risk of the test application.
Testing Process and Toolchain
Integrate all products into one safe battery test system.
Be Prepared for Future Batteries
Design a test system that is modular and upgradable for future battery testing.
Reliable Supplier
Finding suppliers who act like partners and guide you through the complete process – from concept to pre-definition of test.
Specification
AVL Battery Module/Pack TS™ for battery tests typically consist of:
- AVL E-STORAGE SiC™ (battery tester)
- AVL PUMA 2™ Battery (automation system)
- AVL Climatic Chamber for wide-range temperature simulation and humidity
- Overpressure protection via enforced chamber with burst disk and overpressure flap
- AVL Safety Concept (e.g. fire protection surveys)
- Gas alert and ATEX extraction system
- Fire alert and suppression
- Pre-installed media supply network (electricity, air, water)
- Integration of facility management system via testbed safety PLC
| Main Modules | Main Features |
|
AVL E-STORAGE Battery Tester |
Power range up to 2,200 kW / 4,000 A / 1,200 V |
| AVL Climatic Chamber | Temperature range from -40°C to 85°C |
| Measurement instrumentation | No switching time between charging and discharging |
| Fully implemented AVL Safety Concept | Interacting with the Battery Management System (BMS) |
| Pre-installed facility subsystems | Fast rise times combined with high accuracy |
| Defined interfaces to customer infrastructure | Full sinusoidal power feedback onto the main electrical grid |
Complete Battery Competences
Synergy between engineering, simulation, and testing thanks to complete battery competence in-house
Numerous Reference Projects
AVL is a competent partner for any kind of battery development and testing, with serval reference projects
Different Testing Applications Covered
Optimized testing equipment for different battery testing applications up to turnkey solutions with containerized facilities
AVL Automation
AVL PUMA 2™ Battery is our consistent PUMA-based battery test automation solution to test all types of batteries. It lets you re-use your long-time PUMA 2 experience and share knowledge within your teams. You can also share data and parameters across different PUMA testbed types and configurations.
AVL Module and Pack Tester
AVL offers cyclers for all types of batteries, from cell to module and pack testers. The extended test range of our solutions cover UUTs > 800 V (AVL E-STORAGE SiC™) and an output current ranging from ±2 A to ± 1500 A (AVL Cell and Module Tester™).
AVL FEM 4™
The next generation of AVL data acquisition for electric, hybrid and combustion engines provides you with highest measurement accuracy – calibrated according to ISO 17025, high galvanic isolation up to 1,500 VDC for electrification modules and an extended temperature range – 40 ... +80 °C.
AVL Climatic Chamber
Battery packs, modules and cells, fuel cells, e-drives and e-axles must operate safely and reliably in any environment. With the AVL Climatic Chamber you can simulate extreme environmental conditions for these applications in a testing environment.
As a partner with a global presence and with knowledge of battery development, simulation, and production, AVL is a reliable, competent partner in the area of test systems for batteries.”
– Martin Schweiger, Senior System Line Manager, AVL List GmbH
AVL E-Mobility Testing Solutions – Brochure
Tested and Trusted.
AVL Battery Testing Solutions – Brochure
Learn more about our holistic battery testing portfolio and solutions.
AVL Battery Module/Pack TS™ – Solution Sheet
Exploring the limits with maximum safety.
Success Story – “Battery Testing for LABCO”
How AVL supported LABCO BTC in entering the world of battery development.
Success Story – “Valmet Automotive”
AVL battery testbeds support the development of advanced battery systems for xEVs.
For battery cell testing, we offer complete test systems, stand-alone equipment, or even entire turnkey test labs.
Battery tester and emulator for research and development, testing and validation.
AVL´s intuitive automation system for battery testing, from cell to module and pack.
New powertrain technologies require a higher data throughput rate in real time. AVL FEM 4™ enables you to measure all raw data relevant for the characterization of the unit-under-test.
Increase the efficiency and effectiveness of your test lab.
The AVL Customer Services organization consists of more than 700 service- and application engineers worldwide, operating from more than 50 locations. Our global footprint is your local benefit.
AVL’s E-Library is a mindful solution that introduces simplicity when dealing with e-testing complexity, provides a fast track to productivity, and offers reassurance that targets will be met – putting your mind at ease and allowing you to enter the market with full confidence.
Battery packs, modules and cells, fuel cells, e-motor and e-axle solutions must operate safely and reliably in any environment. This can include extreme temperatures and humidity, which cannot be reproduced on the test track or in real test scenarios on the road. This is why we developed the modular AVL Climate Chamber.
Thermal conditions and environment of Units Under Test have strong impacts on real results in driving. For this reason, the thermal simulation must be as exact as possible – which can be achieved via deployment of high performing media conditioning systems.
AVL ThermalLab™ tests the entire VTMS, including all coolant circuits and the refrigerant cycle, under dynamic conditions using model-based testing. The UUT is the complete VTMS embedded in an emulated vehicle while the environment is fully simulated. The entire system can be tested in the lab under realistic driving and ambient conditions.
Battery electric vehicle (BEV) development requires significant adjustments to the development process and its environment.
AVL RACETECH, the motorsport department of AVL, presents the prototype of an innovative H2 internal combustion engine. The power unit is a compact, hydrogen-powered 2-liter turbo engine, with intelligent water injection, which achieves a totally new performance level. The first racing engine that AVL RACETECH is developing and building in-house.
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