The challenge
A new battery pack line needed 100% end-of-line testing covering IP67 leak, insulation resistance, high-voltage functional checks and BMS communication, at line rate, with operator safety guaranteed around live high-voltage packs.
Our approach
We designed a two-station cell with automated pack handling, pressure-decay leak testing, HV test integration and a safety PLC architecture validated to ISO 13849 PL d. Test data flowed to the plant MES with pack serial traceability. A machine-learning model trained on early production data flags packs likely to fail downstream field tests.
The outcome
The cell achieved the 90-second cycle time target, eliminated manual HV handling, and the predictive model has reduced field returns attributed to pack assembly defects.
Representative engagement. Client identity and certain project details are withheld or generalised under confidentiality agreements.