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New End-of-Line Test Process and Machine Design for Automotive Lead–Acid Batteries

The reliability of an automotive battery is its single most important feature, especially for the original equipment manufacturer (OEM) market. To ensure reliability, all automotive batteries prior to shipment are subjected to electrical load tests that are performed in accordance with industry accepted standards. It is essential that the energy discharged from the battery during the test be minimized to avoid the cost and delay associated with recharge. These basic requirements must be considered when defining the ideal high-rate discharge test. Immediately after formation and preferably after post cleaning, the batteries are discharged at high current for a few seconds. The voltage under load at the end of the test is determined and compared with nominal values to deliver a pass/fail decision. This presentation discusses a high-rate discharge End-of-Line (EOL) test machine which is a new approach in terms of its assembly, programming flexibility and the ability to discriminate accurately between acceptable and unacceptable batteries. It will be shown how supplemental evaluation criteria such as Direct Current Resistance (DCR), Alternating Current Resistance (ACR) and the Constant Current Voltage (CCV) discharge curve vs. time can be implemented. The new generation of the EOL, allows a simplified programming of customized test and evaluation profiles to improve the reliability of the results.

Michael Wipperfürth

Sales Manager, CMWTEC technologie GmbH

Michael Wipperfürth graduated in 2001 from the Chamber of Industry and Commerce in Frankfurt/Main as a business economist. For five years, he worked as a purchasing manager at CMW Automation GmbH and in 2006 became its sales manager for Asia and Europe. Michael joined CMWTEC TECHNOLOGIE GmbH in 2009 and since then been responsible for the worldwide sales and marketing of machines in the finishing and formation areas.

Tony Schröer

CMWTEC Technologie GmbH
Business Development

Mr.Tony Schröer graduated 1986 from the Technical University of Flensburg. For four years he worked as R&D engineer for a German supplier of power electronics for telecommunications, then, in 1990 Mr.Schröer went over to a well-known German battery manufacturer where he worked as project manager in the field of formation and assembly for five years.

In 1995 Mr.Schröer joined Digatron Power Electronics and became their Sales Manager in 2000 and their Vice President Marketing and Sales in 2004.

Since 2015 Mr. Schröer is an independent consultant and provides sales and engineering services for the battery industry and supplying companies.

Walter Wipperfürth

CMWTEC technologie GmbH
Senior Consultant