Electrical Function and Component Testing

After the soldering process, the connections and electrical functions of the supercapacitor modules are tested automatically. Electrical Functional and Assembly Test (FCT) Electrical Contact Testing Configurable Functional Tests Error and Threshold Monitoring

The stored energy is discharged in a controlled manner before and after the test process to ensure defined and safe test conditions. Two-stage discharge before the functional test Safe energy dissipation after the test process Monitored operating states and enable conditions

Identification and Traceability

Each test specimen is automatically recognized, and its measurement and test data are uniquely assigned. UID Reading Barcode Scanning Digital Recording of All Test Results MES and Traceability Integration

Safety and Process Functions

Additional protection and testing mechanisms reduce operator errors and safeguard the testing process at high currents. Leak and safety tests Poka-Yoke concepts Automatic product recognition Interchangeable adapters for future product variants

FCT Systems

Supercapacitors in E-Mobility

Supercapacitors are high-performance, next-generation energy storage devices.

They absorb electrical energy within seconds and release it just as quickly. Especially in modern 48-volt vehicle systems, they enable efficient energy recovery, support the powertrain, and stabilize the vehicle electrical system. Thanks to their high cycle stability, excellent safety, and long service life, they are considered a key technology for the sustainable mobility of tomorrow.

Challenges and Concept

Testing 48-volt supercapacitor modules places special demands on test technology, safety, and process stability. Due to the high levels of stored energy and the safety-critical nature of their use in vehicles, all test procedures must be reliable, reproducible, and fully documented.

Blinker, Kamera, Heizung und Assistenzsysteme.

FCT Systems

Außenspiegel

Supercapacitors in E-Mobility

A Safe and Flexible FCT System for Supercapacitors

For this application, MCD Elektronik developed a flexible test solution for electrical functional and assembly testing of the supercapacitor modules. Controlled discharge processes, automatic product identification and comprehensive safety functions create defined test conditions while protecting the device under test, electronics and operator.

Interchangeable adapters allow the system to be extended for future product variants. Poka-yoke concepts, configurable test sequences and digital integration with MES and traceability systems ensure a reproducible and fully documented test process.

System Voltage

48 V

Charging current

up to 20 A

Discharge current

up to 50 A

Scope of Testing and Functionality

The FCT system tests the electrical functions of the supercapacitor modules and combines this with automated identification, safety tests, and full traceability:

Test Setup for Supercapacitor Modules

Overview of the test record

Adapter and Contacting Unit

Adapter for supercapacitor modules

Detailed view of the adapter

Modular test fixture with plug-in connections

After the soldering process, the connections and electrical functions of the supercapacitor modules are tested automatically.

Electrical Functional and Assembly Test (FCT)
Electrical Contact Testing
Configurable Functional Tests
Error and Threshold Monitoring

The stored energy is discharged in a controlled manner before and after the test process to ensure defined and safe test conditions.

Two-stage discharge before the functional test
Safe energy dissipation after the test process
Monitored operating states and enable conditions

Each test specimen is automatically recognized, and its measurement and test data are uniquely assigned.

UID Reading
Barcode Scanning
Digital Recording of All Test Results
MES and Traceability Integration

Additional protection and testing mechanisms reduce operator errors and safeguard the testing process at high currents.

Leak and safety tests
Poka-Yoke concepts
Automatic product recognition
Interchangeable adapters for future product variants

A reproducible and flexibly scalable testing process

Poka-Yoke, automatic product recognition, and interchangeable adapters enable a reproducible inspection process and flexible expansion to accommodate future product variants.

Test Methods Used and Results

Reproducible and Flexibly Scalable Testing Process

To ensure a reproducible and safe testing process, the FCT system combines electrical functional tests, controlled discharge procedures, automatic identification, and comprehensive protection mechanisms.

Defined Test Conditions

Controlled two-stage discharge prior to the functional test

Safe dissipation of stored energy after the testing process

Defined and reproducible initial conditions

Electrical and Functional Tests

Electrical Contact Testing

Configurable Functional Tests

Continuous Error and Threshold Monitoring

Testing of high-current applications with charging currents up to 20 A and discharging currents up to 50 A

Safety and Security

Hardware- and software-based protection mechanisms

Monitoring of Defined Operating Conditions

Defined Approval Conditions

Poka-Yoke and Automatic Product Recognition

Process and Quality Assessment

Automatic assignment of test data via UID and barcode

Digital recording of all measurement and test data

Complete documentation via MES and traceability systems

A reproducible and flexibly scalable testing process

FREQUENTLY ASKED QUESTIONS

FAQS

Supercapacitors (also known as “supercaps”) are high-performance energy storage devices that can absorb and release electrical energy in a very short amount of time. They support the recovery of braking energy, stabilize the 48-volt electrical system, and provide short-term high power for safety-critical systems, such as steering or brakes.

The FCT (Functional Test) system is used during the production of supercapacitor modules. It ensures that electrical functions, safety features, and product quality are maintained throughout the manufacturing process. All measurement and test data are automatically recorded and transmitted to MES and traceability systems. In addition, product data, such as the UID, are stored.

Interlocks and safety covers, as well as monitored discharge processes, reliable high-current connections, and automatic test terminations to protect operating personnel and hardware. Human errors are reliably prevented through the “Poka Yoke” concept, coded interchangeable adapters, and automatic product recognition.

The system enhances process reliability and reduces operator errors. It also improves product quality, traceability, and ensures complete documentation of module testing.

Yes, the modular design with interchangeable adapters allows for the testing of different product variants and facilitates the subsequent integration of new assemblies.