Test Systems for Battery Packs and Modules

For testing battery packs and modules, HORIBA FuelCon offers the Evaluator B test station, providing a performance range up to 1,000 kW.

Like all battery testing systems of the Evaluator B series, the Evaluator B suits for testing batteries of different technologies and can be customized for your testing requirements and applications, based on its sophisticated safety concept.
 

We offer:

A state-of-the-art IGBT technology enables these charge / discharge units for giving discharge energy back into existing grid infrastructures. Thus, running costs during test station operation can be saved.

With typical all-over efficiencies of 95 % or higher, water cooling for residual heat is not required, which reduces the needed investment for the laboratory facilities.

All outputs contain a galvanic separation and are characterized by a high control dynamic and a very low residual ripple.
 

With the controller, all HORIBA FuelCon charge / discharge units can be operated without PC. The well-structured graphic display shows set points and actual values of channel current, voltage and temperate at first sight.

Intuitive operating buttons provide manual setting of set points, critical values or control parameter, which ensures comfortable setup operation of each test run especially for large test fields.

Independently from operating PC and control devices, the intelligent controller manages all critical values and ensures an immediate disconnection of the test item in case the values are exceeded.

With the specially for battery testing designed sequencer technology of HORIBA FuelCon, the controller manages test runs, buffers actual values and realizes the communication with data server or control devices.

The chamber concept we have specially designed for testing high-power cells and safety-sensitive development samples. A non-hazardous test station design is ensured by stainless steel shelves or closed test chambers with sight glass that are available in different dimensions.

The chamber concepts includes several features:

• Discontinuous inertisation
• Control sensor system
• Pressure release
• Minimized thermal load and fireproof ground isolation
• Test item tempering

For the performance of tests in cryogenic ranges or for validations under norm climatic conditions we integrate standard chambers of established manufactures into our approved safety and control concept

Impedance spectroscopy is one of the most effective methods for characterizing battery deterioration factors, as well as for the component and material development. Impedance analysis in combination with charge-discharge cycles enables an optimization of the battery management system.

Impedance spectrum analyzers allow spectroscopy measurement as a stand-alone device or as an integrated component of the battery test station Evaluator B.

With the Evaluator B the battery can be charged or discharged in a fully automated manner while the impedance spectrum is measured.

Examples for typical measurements:

• Impedance spectrum at 100 %, 80 %, 60 % State of Charge (SOC)
• Impedance spectrum after 50, 100, 150 ... cycles
• Impedance spectrum after a stress phase within a driving cycle
   

The battery behaviour during highly dynamic loads is particularly interesting when evaluating hybrid batteries. The internal resistance of batteries significantly affects the maximum current especially at pulse-shaped loads.

Applications:

• Characterizing deterioration causing factors
• Component and material optimization
• Minimizing self-discharging losses
• Optimization of battery management
• Measuring and characterizing internal resistance
• Evaluation of electrolyte losses
• Increasing durability
• Manufacturing process control

The impedance spectrometer is ideally designed for battery testing. The high DC current range up to 1,000 A and the very small impedances within mΩ range guarantee optimal measurement conditions. The Electrochemical Impedance Spectroscopy (EIS), with a frequency range between 200 µHz and 100 kHz, enables the measurement of the typical impedance spectrum of batteries.

Combined with the multiplex module TrueData-MUX different cells of a battery can be tested at the same time. As a result, the battery management system can be optimized.

Within several design processes, for design modifications or within mass production, validation tests are required for simulating typical climatic, electrical and mechanical affects.

HORIBA FuelCon offers a broad range of solutions, tailored to the respectively application conditions:

• Charge / discharge units with climatic chamber
• Charge / discharge units with shaker
• Coupling of climatic chambers and shaker
• Parameter adjustment with control devices
• Communication with battery management systems (BMS)
• Residual bus simulation

After the battery and pack assembly, the quality and parameter control of the produced units is necessary. Therefore, HORIBA FuelCon offers semi or fully automated end-of-line battery testing systems.

These test cells contain the following basic features:

• User-friendly operator interface through touch panel
• Fully automated performance with "one button operation"
• DMC scan including connection to assembling data bases
• Manual or fully automated adaptation
• Functional testing
  • Performance testing
  • Electrical testing including isolation tests
  • Testing and calibration of BMS
  • Integration into assembly automation

After the battery and pack assembly, a quality and parameter control of the produced units is necessary. Therefore, HORIBA FuelCon offers semi or fully automated testing systems.

These test cells contain the following basic functions:

• User-friendly operator interface through touch panel
• Fully automated performance with "one button operation"
• DMC scan including connection to assembling data bases
• Manual or fully automated adaptation
• Functional testing
  • Residual bus simulation
  • Testing of switching operation behaviour
  • Testing of reaction timings
  • Electrical testing including isolation tests
  • Calibration
• Integration into assembly automation