In times of transition towards battery-electric vehicles, test capacities for traction batteries need to be flexible, mobile and quickly available – whether for research, development or quality assurance. To meet these requirements, DSA and Weiss Technik developed the mobile, container-based Plug&Test Lab. The innovative solution covers a wide range of tests and enables standard-compliant testing of high-voltage batteries and other test objects. It meets all relevant safety requirements and provides a cost-effective and efficient, as well as ready-to-use, alternative to stationary testing systems.

Test chamber with two operating modes

The lab can be adapted to individual requirements and customer preferences. It is suitable either for expanding existing testing systems or as a replacement for systems that have failed. In the current version, the test chamber has two operating modes. As a test laboratory for traction battery systems, it works in a temperature range of -40 to +80 °C with multiple inputs/outputs and CAN communication between the automation system and the test object.

In a second mode, it covers an extended range from -60 to +150 °C and simulates a variety of standardised cycles. In both configurations, humidity levels from 10 to 95% RH can be realised. A wide range of electrical and physical tests meets the most stringent requirements. The integrated test software offers predefined standard test scenarios for intuitive programming of individual test sequences.

Short-term installation of new test capacity on a small site

Thanks to its container-based design, the Plug&Test Lab can be set up virtually anywhere, even on a green field site. Its mobility allows new, comprehensive test capacities to be set up quickly in a small area. Time-consuming construction work and lengthy approval procedures are avoided. It is therefore the ideal solution for test field operations and test facilities that require additional test capacities quickly and flexibly.

First testing laboratory sold and commissioned

The first unit of the test laboratory has now been sold and successfully put into operation. Its mobility is also reflected in the laboratory's history so far. It was built at the main Weiss Technik site in Reiskirchen/Hessen and put into operation at its current location at the test partner TüV Rheinland in the border region between Germany and the Netherlands. And soon it will be providing valuable services for the new owner, Bosmal at its new location in Poland.