{"id":15285,"date":"2025-01-09T00:00:00","date_gmt":"2025-01-09T00:00:00","guid":{"rendered":"https:\/\/www.dmcinfo.com\/our-work\/bed-of-nails-battery-management-system-pcb-test-station\/"},"modified":"2025-09-05T15:39:36","modified_gmt":"2025-09-05T20:39:36","slug":"bed-of-nails-battery-management-system-pcb-test-station","status":"publish","type":"our_work","link":"https:\/\/www.dmcinfo.com\/our-work\/bed-of-nails-battery-management-system-pcb-test-station\/","title":{"rendered":"Bed-of-Nails Battery Management System PCB Test Station"},"content":{"rendered":"\n<p>A leading battery company approached DMC for help developing a custom automated test system for their new BMS PCB manufacturing line. DMC expediently engaged with the client to design and develop a solution&nbsp;based on DMC\u2019s proven <a href=\"https:\/\/www.dmcinfo.com\/services\/test-and-measurement-automation\/battery-pack-and-bms-test-systems\/\">Battery Production Test<\/a> platform. Unique client requirements required&nbsp;adding cell simulation functionality, software flash\/programming, and PCB validation tests to DMC&#8217;s BPT standard platform.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-test-specification\">Test Specification<\/h2>\n\n\n\n<p>The functional test specification required:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>BMS firmware flashing<\/li>\n\n\n\n<li>Cell emulation<\/li>\n\n\n\n<li>Thermistor emulation<\/li>\n\n\n\n<li>Temperature and voltage tests<\/li>\n\n\n\n<li>Communication over CAN and serial buses<\/li>\n\n\n\n<li>Analyzing LED status indicators<\/li>\n<\/ul>\n\n\n\n<p>Each BMS test results in a report with metadata identifying the DUT, test system configuration, and test results with limits included.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-systems-engineering\">Systems Engineering<\/h2>\n\n\n\n<p>DMC had to factor in many requirements including&nbsp;test accuracy, cycle time, operator ergonomics, and overall system envelope. DMC leveraged our internal <a href=\"https:\/\/www.dmcinfo.com\/services\/manufacturing-automation-and-intelligence\/control-panel-design-and-fabrication\">fabrication shop<\/a> and carefully selected external vendors like Pickering for robust hardware solutions. The software design leaned on DMC\u2019s existing platforms and tools to minimize costs while maintaining performance and reliability.<\/p>\n\n\n\n<p>DMC divided the hardware design into modular sub-systems: data acquisition box, Bed-of-Nails test fixture, and instrument rack. The rack design housed multiple Pickering LXI chassis containing cell simulation and thermistor cards. The interfaces between these sub-systems were well defined early in the design process, along with consistent communication to minimize design siloing.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-software-design\">Software Design<\/h2>\n\n\n\n<p><p paraeid=\"{74c4e171-5cad-4a8d-86e7-7e5f7587aece}{217}\" paraid=\"727087969\">Software customizability was a major consideration for the client,\u00a0DMC built upon its proven <a href=\"https:\/\/www.dmcinfo.com\/services\/test-and-measurement-automation\/battery-pack-and-bms-test-systems\/\">Battery Production Test<\/a>\u00a0(BPT) platform to meet client&#8217;s software requirements. Some highlights include:<\/p><\/p>\n\n\n\n<p><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Intuitive <a href=\"https:\/\/www.dmcinfo.com\/services\/application-development\/user-interface-design\/\">user interface and user experience design<\/a><\/li>\n\n\n\n<li>Customizable test sequences through NI TestStand<\/li>\n\n\n\n<li>Traceable reports with MES integration<\/li>\n\n\n\n<li>Tracked and version-controlled test configurations (workspaces)<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\" id=\"h-conclusion\">Conclusion<\/h2>\n\n\n\n<p><p paraeid=\"{c8da3933-6bcb-46d2-ac73-ee2baf366785}{61}\" paraid=\"1316297969\">DMC delivered a robust and highly configurable system on a deadline, providing our client with BMS test capability ahead of their full battery pack assembly line. The solution detects manufacturing defects and provides traceable test results to each battery under test.<\/p><\/p>\n\n\n\n<p><p paraeid=\"{c8da3933-6bcb-46d2-ac73-ee2baf366785}{61}\" paraid=\"1316297969\"><strong>Learn more about DMC&#8217;s <a href=\"https:\/\/www.dmcinfo.com\/services\/test-and-measurement-automation\/battery-pack-and-bms-test-systems\/\">Battery Production Test (BPT) System<\/a>, check out this <a href=\"https:\/\/www.dmcinfo.com\/our-work\/power-hil-test-stand-for-an-autonomous-air-vehicle\/\">BMS Power HiL Test System<\/a>, or <a href=\"https:\/\/www.dmcinfo.com\/contact\">contact us<\/a> to discuss your next project.<\/strong><\/p><\/p>\n\n\n\n<figure class=\"wp-block-gallery has-nested-images columns-default is-cropped wp-block-gallery-1 is-layout-flex wp-block-gallery-is-layout-flex\">\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" width=\"768\" height=\"1024\" data-id=\"15282\" src=\"https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165416\/Fig.1-BMS-Test-Stand-with-Bed-of-Nails-Fixture-768x1024.png\" alt=\"Fig.1-BMS-Test-Stand-with-Bed-of-Nails-Fixture\" class=\"wp-image-15282\" srcset=\"https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165416\/Fig.1-BMS-Test-Stand-with-Bed-of-Nails-Fixture-768x1024.png 768w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165416\/Fig.1-BMS-Test-Stand-with-Bed-of-Nails-Fixture-225x300.png 225w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165416\/Fig.1-BMS-Test-Stand-with-Bed-of-Nails-Fixture.png 844w\" sizes=\"(max-width: 768px) 100vw, 768px\" \/><figcaption class=\"wp-element-caption\">Fig.1: BMS Test Stand with Bed-of-Nails Fixture<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" width=\"1024\" height=\"768\" data-id=\"15283\" src=\"https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165415\/Fig.2-Bed-of-Nails-Fixture-Closeup-1024x768.png\" alt=\"Fig.2-Bed-of-Nails-Fixture-Closeup\" class=\"wp-image-15283\" srcset=\"https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165415\/Fig.2-Bed-of-Nails-Fixture-Closeup-1024x768.png 1024w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165415\/Fig.2-Bed-of-Nails-Fixture-Closeup-300x225.png 300w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165415\/Fig.2-Bed-of-Nails-Fixture-Closeup-768x576.png 768w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165415\/Fig.2-Bed-of-Nails-Fixture-Closeup.png 1500w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Fig.2: Bed-of-Nails Fixture Closeup<\/figcaption><\/figure>\n\n\n\n<figure class=\"wp-block-image size-large\"><img decoding=\"async\" width=\"1024\" height=\"768\" data-id=\"15284\" src=\"https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165414\/Fig.3-BPT-Application-Closeup-1024x768.png\" alt=\"Fig.3-BPT-Application-Closeup\" class=\"wp-image-15284\" srcset=\"https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165414\/Fig.3-BPT-Application-Closeup-1024x768.png 1024w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165414\/Fig.3-BPT-Application-Closeup-300x225.png 300w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165414\/Fig.3-BPT-Application-Closeup-768x576.png 768w, https:\/\/cdn.dmcinfo.com\/wp-content\/uploads\/2025\/05\/27165414\/Fig.3-BPT-Application-Closeup.png 1500w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\">Fig.3: BPT Application Closeup<\/figcaption><\/figure>\n<\/figure>\n","protected":false},"excerpt":{"rendered":"<p>A leading battery company approached DMC for help developing a custom automated test system for their new BMS PCB manufacturing line. DMC expediently engaged with the client to design and develop a solution&nbsp;based on DMC\u2019s proven Battery Production Test platform. Unique client requirements required&nbsp;adding cell simulation functionality, software flash\/programming, and PCB validation tests to DMC&#8217;s [&hellip;]<\/p>\n","protected":false},"author":8,"featured_media":126,"template":"","meta":{"customer":"EnerSys","summary":"DMC adapted our&nbsp;Battery Production Test (BPT) standard electrification solution to a user-friendly and cost-effective custom End-of-Line test system for a client&#039;s new Battery Management System (BMS) PCBs.\r\n\r\nTo deliver this solution, DMC developed an automated test system that incorporated a custom Bed-of-Nails fixture to connect to the client&#039;s PCBs and execute a custom developed validation test suite. The system incorporated Pickering hardware for battery emulation, NI hardware for signal measurement, and NI TestStand software for test sequence development.","description":"","customer_benefits":"Test System performs 751 individual health checks with a total average test time of 5 minutes and 18 seconds\r\n Cost effective solution scoped directly to client needs\r\n Flexible hardware and&nbsp;software architecture allows for functionality expansion as needed\r\n Provides product traceability capabilities\r\n Compact test stand design to optimize&nbsp;required plant floor space","components_used":"DMC BPT Software\r\n Pickering Battery Emulation Hardware\r\n NI cDAQ Platform Hardware\r\n NI TestStand\r\n NI LabVIEW\r\n FEASA LED Analyzer","project":"Telco BMS FCT","author":"Josh Rosenthal","notes":""},"work_category":[678,693,704,692,685,702,684,706],"class_list":["post-15285","our_work","type-our_work","status-publish","has-post-thumbnail","hentry","work_category-automotive","work_category-battery-pack-test-systems","work_category-energy-and-utilities","work_category-green-technology","work_category-labview","work_category-semiconductor","work_category-test-measurement-automation","work_category-test-stand"],"yoast_head":"<title>Bed-of-Nails Battery Management System PCB Test Station | DMC, Inc.<\/title>\n<meta name=\"description\" content=\"Explore how DMC developed a custom automated test system for BMS PCB manufacturing, enhancing accuracy and efficiency.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.dmcinfo.com\/our-work\/bed-of-nails-battery-management-system-pcb-test-station\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" 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