Automating the Testing of Battery Modules for Electric Vehicles

The aim of this thesis is to streamline and accelerate a critical yet repetitive laboratory task: testing the correct functionality of battery modules for electric vehicles by simulating realistic operating conditions, including temperature, humidity, acceleration, braking, and steady-speed phases. To achieve this, a custom electronic board and a dedicated PC application are developed to manage all machinery and sensors involved in the test from a centralized control interface. The system enables synchronized communication with devices such as chillers, climatic chambers, cyclers, and battery management systems via protocols including CAN and Modbus TCP. Although the physical setup remains complex and the time required for its preparation cannot be significantly reduced, the implemented solution enables a more efficient execution of tests, both in terms of time and operational flexibility. Operators can run multiple test sequences in succession, monitor key parameters in real time, and interrupt the procedure either gradually or immediately in case of anomalies. At the end of each test, a detailed report is generated, summarizing the conditions and outcomes. The thesis demonstrates that the proposed system effectively simplifies and accelerates the validation process of newly assembled battery modules and packs. Future improvements may include enhancing the graphical interface for better usability and extending the system’s capabilities to support additional types of DUTs, such as inverters, as well as integrating further laboratory instrumentation.