UAV Battery Qualification Bench and Dummy-Battery Architecture

Summary

This work involved developing and realizing repeatable battery qualification and acceptance test bench setups for UAV battery systems. A key part of the work was creating a simulated “dummy battery” architecture using modified BMS and relay PCBs with external resistor-divider circuitry.

Challenge

Battery qualification involves destructive and high-risk test cases such as over-discharge and high-temperature validation. Production batteries should not be unnecessarily damaged during validation, while safety logic still needs realistic electrical behavior.

Approach

• Designed test bench workflows for repeatable qualification and acceptance testing.
• Built a dummy-battery architecture for destructive qualification tests.
• Executed battery characterization campaigns to identify critical voltage thresholds.
• Mapped State-of-Charge behavior for Immediate Landing and Return-to-Home safety logic.
• Prepared TEP/QTP/ATP-style documentation and verification reports for certification activities.

Recruiter takeaway

This project demonstrates hands-on system testing, electrical test setup thinking, safety-critical validation and the ability to turn lab results into certifiable engineering evidence.

Report availability

This is company work, so internal test data and full reports are not published. A public-safe summary is provided here, and additional cleared context can be discussed during interviews.