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High Voltage Battery Tester (HVBT)

The High Voltage Battery Tester (HVBT) verifies the safety requirements for high-voltage batteries and battery modules. In addition, the HVBT ensures the function of the batteries and prepares them for installation.

The High Voltage Battery Tester is a modular system whose functions can be customized according to customer requirements and test conditions.

The HVBT system is integrated into the customer's functional safety systems in the assembly process. The HVBT controls the charging and discharging of the HV battery for production, transport and delivery.

Battery Installation

The electrical testing of the individual battery modules before installation ensures their function and resilience.

In addition, by means of the HVBT, the tightness of the cooling circuits and of the housing of the HV battery can be checked.

In order to identify contact resistances, the HVBT can control systems for high-current charge-discharge cycles. Optionally, faulty connections between individual battery modules can be thermographically identified by means of intelligent image analysis.

Battery Test

Safety-related assembly errors and defective components must be identified before installing the HV battery in the vehicle. For this purpose, the HVBT carries out the necessary high-voltage insulation tests.

Battery Commissioning

The HVBT verifies and flashes the firmware of the ECUs if necessary. Here, the device provides extensive residual bus simulations. To check the battery management system (BMS), low-current charge-discharge cycles can be initiated.


  • High voltage insulation tests to detect assembly errors and damaged insulation
  • Low-current charge-discharge cycle for checking the BMS functionality
  • Control of high current charge-discharge cycle to find contact resistances
  • Optional thermographic monitoring with image analysis for temperature distribution and temperature hotspots
  • Tightness test of the cooling circuits of the battery system and the battery housing

  • Electrical testing of battery modules
  • Charging and discharging of the HV battery for production, transport and delivery
  • Integration of the system into functional safety circuits
  • Verifying and flashing of the ECU firmware
  • Full integration into the PRODIS tool suite

Your Contact

Photo of Michael  Kohlhaas
Michael Kohlhaas
+49 (0) 2408 9492-623

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