Chroma ATE Inc. is a world leading supplier of precision Test and Measurement Instrumentation, Automated Test Systems, Intelligent Manufacturing Systems, and Turnkey Test and Automation Solutions. In recent years, Chroma has been actively cultivating the electric vehicle (EV) testing market, and its newly launched lithium battery pack end-of-line (EOL) automated test solution has been successfully adopted by several of China’s well-known automotive manufacturers. Our solution provides safe, real-time monitoring of the test process and saves up to 6 times the inspection time, significantly reducing the production cost.
Once an automotive manufacturer completes the selection of battery cells and battery pack design, as well as development, it then faces bottlenecks in cost and speed during the process of mass production. The safety of EV battery pack production must be taken seriously as the process encompasses potential danger of high voltage and high energy density. Using an automatic battery inspection system can reduce production costs and improve the throughput effectively, and also ensures the safety of the entire fabrication process. Moreover, manual tests can cause inconsistent results, handwritten data errors, long testing hours, product traceability problems and more. At present, automotive manufacturers request that the EOL test for the finished battery packs before shipment takers 10 ~ 20 min/pcs with real-time monitoring, automatic reporting of traceability, and security protection mechanisms. Hence, the modular and automated test solution has been gradually adopted by many automotive manufacturers for battery production.
▲ Model 8700ATS Battery Pack Automatic Test System
The testing functions applied by the lithium battery pack EOL automated test system encompasses mechanical assembly, high voltage insulation, battery management system (BMS) communication, internal on/off switches, battery unbalance, and temperature distribution, etc. The comprehensive PASS/FAIL tests can be used not only for production line but also for R&D near completion phase or battery pack feeding inspection. Automated testing avoids personal misuse and ensures the safety of operators, which is applicable for the battery modules of electric cars, electric motorcycles and energy storage systems. The main features and specifications of Chroma’s battery pack automated test system are listed below:
- For battery module production or R & D unit test verification use.
- Improve product inspection efficiency.
- Test the battery module for BMS function / connector withstand voltage / consistency / performance.
- Charge and discharge power range: 5kW ~ 500kW.
- Charge and discharge power/current range:0V~1200V/0A~2600A.
- Standard test items include: Insulation test, electrical test, software/communication test and battery performance test.
- Capable of providing customized fixtures to connect the battery modules with automatic control switching function.
The lithium battery pack EOL automated test system can integrate with Chroma’s electrical safety analyzers, switching fixtures, digital meters, and regenerative charge/discharge test systems through an open software platform for diversified testing applications. With the support of Shop-Floor programs and MES handshakes, it is easy to integrate data incorporation and tracking. The test system can also handle different automated production line requirements for PLC, MES, and security mechanisms to provide a more complete customized automated test station.
With 30 years of experience in test and measurement instrumentation, Chroma is able to provide a wide variety of test solutions for power and storage batteries. These include: regenerative battery pack test systems for battery cells, battery modules, and battery packs; BMS test systems; battery pack EOL auto test systems; battery simulators; and super capacitors. These solutions are in use worldwide by manufacturers and third party laboratories.
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Battery Test Solutions