Application Notes : The Fundamentals of Battery Test

Battery pack and module testing is more critical than ever. Today’s engineers face new challenges including increased complexity of the tests and set-ups, long development and test times, addressing safety requirements, and avoiding hazards. Furthermore, testing to the application requires emulating real-world conditions by responding to communication signals from the battery, system or external devices. Although testing batteries may seem like a simple task, there are many challenges due to their complexity and hazardous nature. There are several pain points that you should overcome.

Summary of Pain Points for Battery Testing

Battery testing takes a very long time

Battery testing and preparation takes a very long time and chemical reactions can’t be rushed. In addition, understanding battery behavior requires re-running tests to address the “what if” scenarios, which takes a significant time. For example, many EV manufacturers are running accelerated life cycle tests that can take as long as 6 months. ­

Errors lead to re-running tests

Due to the complexity of battery testing there will likely be errors. Yes, Murphy’s Law does apply. Tests will need to be re-run and there are no short-cuts to save the time that’s been lost. ­

Batteries are hazardous

Batteries have high voltages, high currents, toxic chemicals, electrolyte leakages and environmental issues that raise huge safety risks and consequences. ­ 

Battery testing requires large and expensive equipment

Battery test equipment takes up floor space and requires a capital investment. That’s why it is important to select the right test solution that is flexible for a variety of applications and needs. ­

Data collection, analysis and management is time intensive 

The time it takes to collect multiple sets of data, run queries, analyze and process the data, can take up to several months or longer. ­

Testing is different for each application

Testing requirements differ for each application. Getting solid answers for seemingly simply questions can turn into decades of testing. ­

Integration of multiple instruments and software takes time

Multiple pieces of hardware and software requires integration beyond the battery tester including DAQs, relays, chambers, digital I/O & CAN communication. The complexity of the entire test system requires automation, significant test development and integration time and effort.