{"id":40009,"date":"2025-12-17T10:00:00","date_gmt":"2025-12-17T15:00:00","guid":{"rendered":"https:\/\/www.dmcinfo.com\/?post_type=our_work&p=40009"},"modified":"2025-12-10T11:21:35","modified_gmt":"2025-12-10T16:21:35","slug":"powering-up-an-ev-battery-production-line-with-dmcs-bpt-platform","status":"publish","type":"our_work","link":"https:\/\/www.dmcinfo.com\/our-work\/powering-up-an-ev-battery-production-line-with-dmcs-bpt-platform\/","title":{"rendered":"Powering Up an EV Battery Production Line with DMC\u2019s BPT Platform"},"content":{"rendered":"\n

Summary<\/h2>\n\n\n\n

DMC worked with a major automotive OEM that needed to expand testing capacity for their new electric vehicle (EV) production line at their high-volume assembly plant. Their existing end-of-line tester was slow, inflexible, and deeply coupled with the overall line builder\u2019s PLC workflow. Furthermore, the test provider had a proprietary test sequence editor that only they could support. This created a challenging dependency on a singular test provider for new features and updates to their test process. The OEM wanted to remove that dependency by using industry-standard testing tools and software platforms.<\/p>\n\n\n\n

To add to the challenge, the OEM’s product development team was constantly revising their test requirements while simultaneously needing to begin building up their production test cells. We see this as a common trend among our customers: a race to get to market first, to capture market share and reduce overall product development costs. As a result, the traditional \u201cwaterfall approach\u201d of developing a product and then creating a test solution around that prototype just takes way too long. With an agile\/lean new product development approach, they are seeking to parallelize product design and software development with the design, build, and commissioning of the test systems required to validate their \u201cstill evolving\u201d products.<\/p>\n\n\n\n

DMC and our close partner, NI Emerson<\/a>, were introduced to the OEM’s Test Engineering Team and recognized the customer\u2019s challenges as an excellent opportunity to showcase DMC\u2019s Battery Production Tester (BPT) framework<\/a>, which is built on top of NI\u2019s TestStand software platform. DMC had successfully used BPT as the foundation for numerous battery test projects over the past few years, so we knew it would provide the OEM with both the value and flexibility of NI TestStand, along with the simplicity and refined features they enjoyed in their incumbent battery test provider\u2019s solution.<\/p>\n\n\n\n

Replacing the incumbent solution turned out to be no small challenge, with many factors, including politics and familiarity with legacy approaches posed real obstacles for adoption of the DMC BPT. Ultimately, though, it was hard to argue with the results. DMC deployed our BPT platform on the first line, integrating seamlessly with the OEM\u2019s existing hardware and controls while delivering faster cycle times, comprehensive test coverage, and complete data traceability.\u00a0 The BPT platform allowed for rapid test development. Within 1 week of being onsite with the OEM\u2019s new battery pack, the battery cycler, and the other test equipment at the customer site, DMC had a complete test up and running. The OEM told us that it usually took their previous test supplier over a month before the software framework was operational enough to run a full test on their packs, so this was clear value to them: ensuring the project stayed on track and met production timelines. It is also worth mentioning that DMC\u2019s decades of battery test expertise played a critical role in helping the OEM overcome roadblocks with their BMS (battery management system) flashing process, which allowed us to provide the customer not only the tools but the expertise to quickly stand up a battery test line.<\/p>\n\n\n\n

The result of our work together was a future-proof, software-centric solution that displaced a decade-long incumbent and positioned the OEM for scalable growth. DMC is now working with this same customer to deploy the BPT solution to over a dozen other EV and Plugin Hybrid EV (PHEV) battery pack production lines. The project has not only strengthened the customer\u2019s battery test capabilities but also resulted in numerous updates, improvements, and hardening of DMC\u2019s BPT platform, which we\u2019re excited to share with other customers looking to optimize their battery test operations.<\/p>\n\n\n\n

Figure 1: DMC\u2019s Battery Production Test (BPT) Software. Shown Screen: BPT\u2019s low-code BPT Socket Test Overview Screen<\/strong><\/p>\n\n\n\n

\"Figure<\/figure>\n\n\n\n

Customer Benefits<\/h2>\n\n\n\n