New Energy Vehicle Test Solution

New Energy Vehicle BMS Automated Test Solution

The New Energy Vehicle BMS Automated Test Solution is designed for BMS validation, engineering launch and production testing. It integrates high-voltage safety testing, functional testing, CAN/LIN communication, analog acquisition, relay control, fault injection, barcode binding and traceability into a stable and maintainable automated test platform. The solution can be customized based on test specifications, product interfaces, production takt and traceability requirements to improve consistency, reduce manual operation risk and build reusable test workflows.

Customer Challenges

  • BMS testing involves high-voltage safety, low-voltage functions, communication protocols and multi-channel signal acquisition.
  • CAN/LIN communication, relay control, sampling accuracy and fault response require stable and repeatable automated validation.
  • High-voltage testing requires robust safety interlocks, exception protection, permission control and test-flow management.
  • Production testing requires barcode binding, key parameter logging, test logs and traceability.
  • Vehicle platforms and BMS models evolve over time, requiring configurable and extensible test systems.

Solution Approach

  • Break down BMS test specifications into high-voltage, low-voltage, communication, sampling and protection test flows.
  • Integrate high-voltage power supplies, electronic loads, DMMs, DAQ, relay matrices, CAN/LIN interfaces and safety interlock modules.
  • Develop automated test software for sequence configuration, instrument control, communication messaging, result judgment and exception handling.
  • Design BMS-specific fixtures, interface boards and harnesses to reduce wiring errors and maintenance cost.
  • Connect barcode, database, MES or file servers to close the loop for records, reports and quality traceability.

Core Capabilities

BMS functional test automationHigh-voltage testing and safety interlockCAN/LIN communication testingAnalog acquisition and accuracy validationRelay control and fault injectionReports, logs and data traceability

Deliverables

  • BMS automated test software platform
  • Electrical integration and safety interlock design for high-voltage test stations
  • CAN/LIN communication test modules and message configuration
  • BMS test fixture, interface board and harness design
  • Test item configuration, report templates and traceability interfaces
  • On-site commissioning, operator training and maintenance documentation

Business Value

  • Improves BMS test-flow consistency and reduces operator variation.
  • Reduces high-voltage test risk through safety interlocks and exception protection.
  • Automatically captures CAN/LIN communication and key electrical parameters for quality analysis.
  • Stores test data, barcode records and reports for production traceability.
  • Platform architecture can be extended to more BMS models and test items.

Specifications

Applicable Products
NEV BMS master boards, slave boards and battery-management control modules
Key Tests
High-voltage testing, low-voltage functional testing, CAN/LIN communication, sampling accuracy, relay control and fault response
Typical Integration
High-voltage power supply, electronic load, DMM, DAQ, relay matrix, CAN/LIN interface, barcode and MES
Traceability
Product barcode, test parameters, results, exception logs, report files and MES/database interfaces

Planning a New Energy Vehicle BMS automated test system?

onTAP can provide integrated services from solution design to on-site delivery based on BMS interfaces, test specifications, high-voltage safety requirements, CAN/LIN protocols and production traceability needs.

Contact onTAP