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Automotive battery manufacturerQuality verification dept

Wanted to conduct four electrical safety tests effectively.
Multifunction safety tester supporting IEC61851 compliance test for battery.

All over the world, governments attempt to support the transition to e-mobility. Over the past few months, several major automakers have announced plans to add large numbers of electric cars along with hybrids and plug-in hybrids to their lineups. Some have even announced to stop selling cars that don’t feature some degree of electrification.
Company P have been working on enhancement of productivity to meet the increase in demand for batteries.

The Problem

Wanted to conduct required electrical safety test to comply with IEC61851 for battery.

The Quality verification dept. have wanted to improve efficiency of final inspection test before shipment. To increase the productivity in the production line, it was a vital step to avoid bottlenecks in our inspection process. IEC61851 applies to EV supply equipment for charging electric road vehicles. Electric road vehicles cover all road vehicles, including plug-in hybrid road vehicles (PHEV), that derive all or part of their energy from on-board rechargeable energy storage system. It includes the requirements for electrical safety for the EV supply equipment. It was urgent task for Mr. S at Quality Verification Dept. to configure the test environment to perform the test effectively. The company P had each test instrument for required safety tests, such as Dielectric voltage test, Insulation resistance test, Protective bonding test, and Leakage touch current. Mr. S said, “We were concerned about the cost of managing assets, and it was time to investigate more cost-effective test measurement equipment management”. Mr. S found some multifaceted safety testers like 4-in-one type, which performs primary electrical safety test including AC hipot, DC hipot, Insulation Resistance, and Ground Bond test. Those multi-function testers increase productivity and save valuable space on the production line. Even so, the company P had held the plan to introduce the 4-in-one type safety tester on fears of uncertainty about the capability to perform the compliance test. Under these circumstances, Mr. S was at a loss without any ideas specifically what to do.

Key Aspects of the Problem

  • Configuring test environment to perform required safety test on batteries complaint with IEC61851.

  • Having difficulties securing installation space of multiple test instruments.

  • Multi-function safety tester had not been introduced due to uncertainty over capability to perform the compliance test.

How was this problem solved?