DEVELOPMENT - INDUSTRIALIZATION - SERIES PRODUCTION

How Handtmann made a high-voltage storage system for small commercial vehicles ready for series production in ten weeks.

The project at a glance.

10 weeks

CAD model to vehicle ready for homologation

37.7 kWh

Energy content of high-voltage storage

100 %

Leak test every unit produced

355 V

Nominal voltage system

THE INITIAL SITUATION

What ABT e-Line needed - and why it was challenging.

ABT e-Line electrified variants of small commercial vehicles – under the typical constraints of the market: tight packaging, a clear focus on costs, an ambitious schedule and high demands on reliability and documentation.

From the interface definition to the running production line.

Handtmann Systemtechnik supported the project as a full partner – from the initial system design through to reliable series production.

System architecture & integration

Crash-proof housing design in welded steel construction, manufactured by Handtmann. Electrical and electronic integration of 16 Li-Ion modules, BMS and junction box to form a complete system ready for installation.

Testing & protection

Extensive electrical tests on individual components and the entire storage system. 100 % leak test of every unit produced. Complete traceability and documentation as the basis for homologation and series start-up.

Series production from the first prototype

Ready-to-install, tested high-voltage storage systems from the very first prototype. Scalable series production line with complete quality assurance – from prototype to stable large-scale production. The same production quality from day 1.

THE RESULT

Ten weeks. Ready for homologation. In series production.

It took ten weeks from the final CAD model of the battery to the vehicle ready for homologation. The vehicle is on the road. The line is running. And Handtmann Systemtechnik has proven what end-to-end expertise – from development to series production – means in practice.

The technical facts.

Parameter

Value

Application

Small commercial vehicles (electrification)

Nominal voltage

355 V

Energy content

37.7 kWh

Weight

330 kg

Dimensions (L × W × H)

1,750 × 950 × 260 mm

Mechanical design

Steel frame with sheet metal cover, crash-resistant design

Electrical design

16 individual modules incl. central BMS (Battery Management System)

Quality assurance

100% leak test, full traceability and documentation

Individual battery & ePowertrain systems

Customized development for specific requirements – from system architecture to series production.

To individual systems

Industrialization & series production

Scalable line production for complex battery systems – from small series to large series.

On industrialization

Concept and series development

End-to-end development expertise from the initial system architecture through to series release.

For concept and series development

Battery systems - Overview

Standardized and individual battery systems and system integration from a single source.

To the battery systems

Similar project? Talk to us.

What we have done for ABT e-Line, we can do for your project. The first step is a technical discussion – about your requirements, your schedule and what is feasible.