Advanced Test Solution for New Energy Parts – Chroma Multi-Channel Battery Simulator

Chroma ATE Inc. was invited to attend the IFEEC 2017 (International Future Energy Electronics Conference) held in Kaohsiung to introduce the new product for battery simulation. The battery simulator can perform simulations on the units that are critical to the booming EV industry such as DC charging pole, on-board charger, and DC/DC Converter, etc. for product verification.

Battery Simulator Soft-panel

As more and more energy conversion products such as motor driver, OBC, DC/DC convertor, and power conversion system (PCS), etc. use battery as the power source, a battery simulator is required for product quality verification. Battery suppliers may not be able to supply batteries of various kinds such as flow battery, sodium sulfur storage battery, and lithium-ion battery with different charge/discharge characteristic curves during product development.

The battery characteristic is nonlinear which is easily affected by temperature, charge/discharge current, aging cendition, and efficiency ,cannot replicate the same characteristic for repeat testing. As time is required to charge or discharge a battery, it makes instant output voltage change impossible for the real battery, which is quite inconvenient when testing the power converter’s upper and lower limits. Most importantly, the large capacity battery is big in size and will age after long-term use. It costs a lot for replacement, plus if the battery is damaged, overcharged or over discharged. It could easily cause safety hazards. In the lab, it is not recommended to set up large capacity batteries, but rather to use a battery simulator for testing.

What functions are required for a battery simulator?

  1. Battery internal resistance setting: The main task of a battery pack is to provide energy to the developed products. When the charged/discharged current is added to the battery pack, the voltage of the battery pack changes instantaneously in a short time due to the impact of the battery internal resistance.
  2. Battery capacity setting: The DC input voltage operating range should be clearly specified in the developed product specification, which is related to the battery pack capacity and output voltage.
  3. Battery voltage point setting: The usage of the battery pack varies with products, and the frequently seen battery management items are 6 voltage level including overcharge voltage, over discharge voltage, upper limit operating voltage, lower limit operating voltage, full charge voltage, and full discharge voltage.

Chroma’s multi-channel battery simulator is easy to use. The multiple embedded channels can test different DUTs at the same time, and read the test results in real time. The rapid setup of common battery parameter can simulate the charge/discharge voltage and IR state of a battery cell under normal, high and low temperatures. The battery cell parameters can convert battery pack state to set the operating and protection range. Moreover, it can set the initial state of output voltage for product testing and verification without waiting for the charge and discharge time like the real battery pack.

Battery Simulator Main Panel

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Battery Test Solution

ITC – The world’s Most Influential Professional Testing Technology Conference Held in Asia for the First Time

Chroma ATE Inc. was invited as one of the opening keynote speakers to address the convergence of electronic and semiconductor systems, and its impact on testing technology

The ITC-Asia (International Test Conference) successfully held on September 13-15 in Taipei, was a flagship conference in test technology. It gathered the IC test and design professionals around the world to confront the challenges the industry faces, and learn how these challenges are being addressed. The conference was dedicated to the process and design improvement of software and hardware – covering design verification, test, diagnosis, failure analysis, components, systems and application software.

To cope with the needs of complex process and system integration derived from IoT, cloud computing, automotive electronics and other emerging applications, the ITC moved to Asia for the first time and co-located with SEMICON Taiwan in 2017. The conference linked the supply chains from semiconductor design in the beginning to IC packaging and testing at the end to boost collaborations in creating more potential business opportunities. Three days of consecutive keynote speeches, industry topics, call for papers and technical courses, explored and analyzed the latest test technology trends with focuses on popular topics including the newest IoT, automotive electronic testing methods and safety standards, as well as the advanced multi chip packaging test and repair technologies.

I-Shih Tseng, the ISS BU general manager of Chroma ATE Inc. was invited as one of the keynote speakers in the opening to discuss the semiconductor testing technology from the perspective of a testing equipment supplier. While we enjoy the convenience and brand new experience brought by high-tech, it is a huge challenge for semiconductor chip producers and test equipment providers as the test is no longer just electronic and circuit testing, but different applications associated with many aspects such as mechanical, optical components, temperature, and even chemical composition.

I-Shih Tseng, the ISS BU general manager of Chroma ATE Inc.
▲I-Shih Tseng, the ISS BU general manager of Chroma ATE Inc.

Semiconductor test has evolved to a level of safety, responsibility and reliability. The IC quality is absolutely important for self-driving cars because it concerns personal safety. When the car is driving in different environments, the temperature can change from high heat to freezing as well as high winds and rain all make the IC chip’s reliability a necessity. Moreover, for new applications, such as in VCSEL 3D image sensing, it has to be sure that it is no harm to people. All of these new applications provide a challenge to chip manufacturers and test equipment manufacturers for their ability to keep the car safe for drivers.

This means that semiconductor test equipment manufacturers need to work with customers earlier in the design process. Chroma ATE has been a Turnkey Solution provider with core technology in measurement since 2011, and is the only manufacturer equipped with testing and automation capability. Chroma’s products are mainly used in communication (FPD, color and video, optical components, power electronics, passive components, electrical safety, thermoelectric temperature control and automatic optics), semiconductor/IC, and clean technology (EV, green battery, LED lighting and solar energy) industries to effectively improve the quality of customer products and production efficiency in helping customers enhance their competitiveness.

Chroma has many product lines to fulfill the needs of semiconductor testing by supplying various kinds of equipment from R&D to mass production such as large ATE test systems, sorting machines and compact PXI test platforms, all of them have complete corresponding products to give customers the most appropriate selection. The complete semiconductor solution of Chroma covers different wafer test applications including consumer chips (microprocessors, audio chips, computers/mobile peripherals, etc.), power chips (linear regulators, DC converters, AC converters, LED drivers, etc.), radio frequency chips (wireless network, blue, blue, etc.), power chips (such as microprocessors, audio chips, computers / mobile peripherals, etc.), RF chips (wireless network, Bluetooth, mobile communication, etc.), and chips for specific testing areas (image sensors, radio frequency identification, etc.)

New IoT applications Initiate comprehensive semiconductor testing needs

Internet of Things (IoT) digitizes the real world by narrowing the scattered information and consolidating the digital information of things. It has a broad market and application prospects that is structured in three layers; sensing, network and application. Ranging from logistics and transportation, health care, smart environment (home, office and factory) along with personal and social areas, almost anything can be closely related to IoT. The IoT chip has been widely used in network and various types of sensors. For different applications in a test environment, the way to ensure that each IC’s function, performance and quality meet the standard is specifically important. Chroma’s Semiconductor BU general manager, George Chang, indicated that to cope with diversified applications, semiconductor wafer testing must incorporate a variety of test items including temperature, radio frequency (RF), precision and speed, to meet all types of IoT applications and customer needs.

Chroma provides complete semiconductor test solutions including SoC / VLSI/ Analog test solutions, IC test handlers, PXI IC test platforms and equipment corresponding to various types of IoT applications in testing embedded processor, MCU, RF MUC, Light Sensor, Magnetic Sensor, G-Sensor/Gyro, CMOS Image Sensor, Finger Print Sensor, Laser Diode, PMIC), and diversified wireless network implementation.

The widespread use of IoT creates a huge demand for micro control units and sensors, which lead to fierce competition in cost and production. As electronic products are always aiming for high cost-performance ratio with better functionality, Chroma is capable of providing competitive test instruments that are flexible to integrate with other equipment and automated systems to meet the demands for increased testing requirements and cost savings.

AI, smart driving, system level and burn-in test ensure final quality of IC

In light of the evolution of semiconductor process and packaging technology, the capabilities of ICs used in consumer electronics, automobiles, internet of things and artificial intelligence are getting more powerful with increased packaging density. Herbert Tsai, the ISS BU deputy general manager of Chroma ATE Inc. pointed out that for the complex packaging products such as SoC/SIP/3D ICs, besides inspecting the power and signal through traditional automated test equipment (mixed single ATE), the System Level Test (SLT) and Burn-in (BI) inspection process are also applied to do a comprehensive testing on IC to ensure its final quality.

As the IoV (internet of vehicle) and smart driving are growing trends, many car manufacturers have implemented ESC (electronic stability control) systems to receive and send signals through the sensor, camera, lidar and RF equipped on the car. When the system has collected the information from each component, it will quickly analyze and evaluate the vehicle status, and give commands to correct the steering wheel, slow down, brake or alarm. This means the system must have powerful semiconductor components to support the overall operation. These automotive systems have to remain in normal operation even under extreme conditions as they are related to driving safety. For varied driving environments, the demand for tri-temperature system level testing (Tri temperature SLT) on car chips is rapidly emerging. The product quality of car chips can be assured after rigorous and long-hour high/low temperature testing.

In recent years, the development of AI chips has been the frontline of first-tier manufacturers. The development of artificial intelligence at this stage is based on parallel computing technology and the depth of deep learning. Through the robust capabilities of self-learning and computing inside the chip, the equipment or systems are able to react properly in time. However, these types of high level chips (GPU/FPGA) are very expensive with strict quality demands, and passing through long hours of SLT/Burn-in test is the way to guarantee that every chip can operate normally under high temperature and high voltage environments.

Chroma has been dedicated to FT / SLT Handler technology research and development for a long time. In addition to the desktop equipment for the design house, Chroma also provides multi-functional and efficient test equipment for designers to use. Moreover, Chroma has introduced multi-probe tri-temperature test equipment to satisfy customer’s demand for mass production. The test technologies proprietary to Chroma can also be customized to meet customer needs providing the best test solutions.


Chroma’s 17040 regenerative battery pack test system reduces power consumption and provides dual modes for battery charge/discharge test and battery simulation to test battery connected devices.

Chroma ATE Inc., a leading provider of power conversion test equipment, announces the release of the 17040 Regenerative Battery Pack Test System. The 17040 test system is a high precision system specifically designed for secondary battery module and pack tests as well as battery simulation. It has a regenerative function to greatly reduce power consumption during discharge and ensure a stable power grid without generating harmonic pollution on other devices even in dynamic charge and discharge conditions. It is capable of recycling the energy discharged (Eff. >90%, PF >0.95, I_THD <5%) back to the grid reducing wasted energy that is discharged traditionally in the form of heat resulting in reduced HVAC requirements. The 17040 is available in four voltage (up to 1,000VDC) and current ranges with auto ranging, high accuracy current/voltage measurement (±0.05%FS/±0.02%FS), 2ms current slew rate, and 1ms data acquisition.


Chroma’s 17040’s also have built in parallel channels and dynamic profile simulation functions. The parallel capability increases the charge and discharge current and power to its maximum, increasing its efficiency and flexibility. The dynamic profile simulation allows the user to load a battery waveform of a given drive profile in either current or power mode to meet NEDC/FUDS requirements. Its bi-directional architecture ensures that current will not be interrupted during the charge and discharge transition state so it provides an accurate simulation of driving conditions in line with ISO, IEC, UL and GB/T international testing standards.

The Battery Simulation mode is featured to test battery connected devices. When a connected device is under development, the 17040 can simulate the battery to verify whether or not the device is functioning as designed. In addition, the 17040 can control the SOC status of different batteries. Users can upload required battery curves to test the DUT for charge and discharge status. The 17040 can also perform battery and DUT collocation evaluation tests in advance that apply to the motor driver for vehicle start-stop systems, light EV electronic controllers, car mounted chargers, etc.

Multiple safety features are built in to the system including Over Voltage Protection, Over Current Protection Check, Over Temperature Protection, and external parameter detection to ensure protected charge/discharge testing on the batteries. Additionally, data loss, storage and recovery are protected against power failure.

Chroma’s Battery Pro software provides users with flexible test editing functions to perform independent channel tests, detailed reports in customizable formats, and abilities to meet various requirements of battery packs with high safety and stability. Software/hardware integration and customization capabilities include BMS, data loggers, chambers, external signals, and HIL (Hardware in the Loop).

(Battery simulator main panel, DCR setting, Battery characteristics V-SOC curve setting screen)

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Chroma’s Battery Production Line Automated Test Solution Adopted by Famous Automotive Manufacturers in China

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▲  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.

For any questions regarding these battery test solutions, please provide your contact information. We will reach out to you for further service.

Battery Test Solutions