Automotive HV Battery System Trainer

This "High-Voltage Battery" system trainer is built around an original high-voltage battery. It contains four lithium-free battery modules along with the activation and monitoring components. The trainer is mounted on a mobile frame and has a lockable fault switch box.

The High-Voltage Battery in the Original Vehicle

In the vehicle, the high-voltage battery is cooled by the coolant of the vehicle's regular cooling circuit and is configured as 24s1p. The original battery has a nominal voltage of 352 V.

The switching unit contains two power contactors, P (plus) and M (minus). The high-voltage system fuse is also inside the switching unit. It also contains a current sensor and, to allow DC charging, two DC charging contactors: DC charging contactor 1 (plus) and DC charging contactor 2 (minus).

Each contactor has voltage taps upstream and downstream of it. This lets the contactors be fully monitored and allows a sticking (welded) contactor to be detected.

Design of This Trainer

• High-voltage battery based on Audi technology
• Lithium-free design
• Original battery housing
• 4 battery modules, 1 of them replaceable
• Fault switch box
• Pilot line
• Diagnostic connector
• Self-diagnosis capable
• Key switch

Faults

• Insulation
• Equipotential bonding
• Module connector
• Module temperature
• Module voltage
• Contactor
• Pyrotechnic igniter
• Smoking battery (optional)