MK Test Systems bring flexible automation to EV battery testing

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MK Test Systems are bringing their automated, computer controlled HV (high voltage) test systems to the battery sector.


The Automeg ® product range has been used in the demanding sectors of aerospace, defence and rolling stock manufacture and maintenance for the past 30+ years.  The systems have developed a reputation for ensuring the integrity and performance of electrical systems and power distribution systems.


The world’s leading EV truck and bus manufacturing facilities are increasingly using Automeg, including Daimler Truck North America.  Typically providing HV testing up to 6000VDC and dielectric withstand (HiPot) testing up to 3500VAC, these systems take advantage of the many years of experience MK has gained in testing rolling stock systems where similar voltages are commonplace.


A recent EV truck application made use of MK’s loop test technology, whereby the bonding resistance of ground circuits on an equipped chassis is automatically tested for overall resistance.  Then, the current flowing through each leg of the network of parallel circuits is measured to enable the detection of high resistance joints.  These high resistance joints could ultimately lead to hot spots and compromised vehicle safety.  See our DTNA case study for more details.

Battery testing requirements

EV battery testing makes use of many of the standard features of the MK Automeg test system for:

  • Ground bond test at varying programmable current
  • Pack connection and weld measurement and verification
  • Terminal resistance measurement
  • Terminal capacitance measurement
  • High current measurement and switching
  • High voltage insulation test and controlled rapid discharge
  • High voltage dielectric withstand (HiPot) test and controlled rapid discharge
  • Function test of internal pack contactors and relays
  • Function test of high voltage interlocks
  • Resistance measurement and verification of fuse paths


Once the range of standard MK test modules has been selected and built into a test console, MKAT ® software is used to create specific test sequences to suit a particular battery cell.  As new battery cells are developed, the user simply creates a new test program to suit that cell.


A single button press launches the test process once the system is connected to the battery cell.  Test results are delivered in a report format and are automatically logged and archived.  Digital record keeping ensures full traceability and enables trend analysis.  In this way, Automeg and MKAT support continuous product and process improvement, as well as IoT and Factory 4.0 targets.


Standard capability of the MK Automeg system includes precise continuity resistance measurement, low voltage isolation testing, high voltage insulation measurement, high voltage AC HiPot testing, high current switching and measurement, and function test stimulus. All of these are routed via a range of relay modules.  This provides fully automatic measurement of high density circuits.