Solution for CCS testing system for wiring harness

1、 Industry background:

CCS (Cells Contact System) testing is aimed at testing the electrical connection structural components used in the power batteries of new energy vehicles. These structural components are usually composed of FPC (flexible circuit board), plastic structural components, copper aluminum bars, etc., mainly divided into two types: module sampling component FPC and module sampling component wiring harness. Due to the rapid development of new energy vehicles, the application of FPC and CCS in new energy vehicles is becoming increasingly widespread, and the requirements for their product reliability are also increasing.

2、 Application requirements:

1. Short circuit test.

2. Temperature control resistor test.

3. Welding resistance test.

4. AC/DC withstand voltage test

5. DC insulation resistance test.

3、 Solution:

The CCS (Integrated Busbar) comprehensive testing equipment developed by Ruijie Intelligent is used for functional testing of wire harness integrated components of lithium battery modules and battery packs. After the product is manually plugged into the testing harness, this testing equipment scans the barcode or QR code and the traceability system and software confirm that the product information is OK. The corresponding testing program is automatically retrieved for fully automated testing, and the test results are automatically judged to be qualified. An alarm is triggered for non-conforming products, and the test data is automatically recorded and saved locally. The results are then uploaded to the MES traceability system.

The automatic testing system adopts an open hardware and software architecture, and is equipped with customized testing equipment such as AC/DC withstand voltage insulation tester, DC low resistance tester, multi-channel scanning unit, and high-voltage isolation unit according to the functional and performance testing requirements of the tested product; By using industrial computers equipped with customized upper computer software, we provide users with a complete and reliable testing solution for research and development precision testing, high-speed production testing, quality inspection testing, and other customized testing needs.