Evaluating the Sinexcel BCTS series high-capacity battery pack testing system

1. Introducing the Battery Pack Testing System (BCTS) series of testing equipment.

The breakthroughs in the electric vehicle (EV), electric bus (E-Bus), and large-scale energy storage systems (BESS) industries have placed stringent testing standards on battery packs. Battery pack testing plays a vital role in research and development (R&D), manufacturing quality control, and operational safety assessment.

The Sinexcel BCTS Series (Battery Pack Testing System) is specifically developed for testing high-capacity battery packs. This pioneering system utilizes a three-level AC scheme combined with multi-gear current switching based on operating parameters. This solution serves a wide range of purposes, from manufacturing and quality verification to electrical characterization analysis, recycling, and battery recovery.

2. Superior power range and high voltage response capability (EV/Bus)

• - For high-capacity battery packs in electric cars and electric buses, the testing system must simultaneously meet all three criteria: high voltage, high current, and continuous operation capability.
• - Wide test voltage range: The system supports a flexible charging and discharging voltage range from 30V to 1250V (or 6V–500V/1000V depending on the model configuration), perfectly compatible with high-voltage battery systems in passenger EVs, commercial vehicles, and electric buses.
• - Wide current range and parallel connection: Output current per channel ranges from -300A to +1200A (or up to 2000A). Notably, the BCTS Series allows parallel connection of channels up to 4800A while maintaining extremely high accuracy (±0.05% FS).
• - Maximum power range: The total output power can be flexibly adjusted from 300 kW to 1.6 MW, fully meeting the requirements for heavy load testing in specialized laboratories.
• - Accuracy and Response Speed: Voltage and current measurement accuracy reaches an ideal level of 0.02% FS (or 0.05% FS). The current rise time is extremely fast (≤3ms - 5ms) and the charge/discharge state transition time is only (≤5ms - 10ms), ensuring accurate recording of all voltage and current fluctuations.

3. Flexible modular structure and scalability.

• - A major advantage of the BCTS Series is its modular design philosophy.
• - Optimized investment costs: Businesses can start with a moderate capacity configuration and easily upgrade and add modules to increase total capacity as production scales up, instead of having to replace the entire lab system.
• - Real-world drive simulation testing: The system allows direct loading of dynamic driving scenario data files (starting, climbing hills, regenerative braking) from Excel files with a capacity of 3 million to over 10 million lines of data, and ultra-fast scenario response times of 10ms to 50ms.
• - Green Energy Feedback: Energy released from the battery pack during discharge is fed back into the grid or directly transferred to charging channels with a feedback efficiency of 95% - 96% and THD harmonic distortion of less than 3%. This eliminates heat generation, significantly reduces electricity costs, and protects the environment.
• - Versatile peripheral connectivity: Seamless integration with BMS battery management systems, temperature chambers, water chillers, temperature/pressure sensors, and common communication standards such as CAN, CANFD, and RS485.

4. Safe operation and intelligent data management

Dedicated BTS software: Allows centralized management of multiple independent channels, setup of complex test cycles (CC, CV, CP, CC-CV, CR, DCIR, Pulse charge), automatic DCIR resistance measurement, and high-speed data logging every 10ms.

Dual Safety & Data Protection Mechanism: Fully integrated hardware and software protection features (reverse polarity, overvoltage, overcurrent, disconnection). In the event of an AC power outage, the system automatically records the current state and resumes the testing cycle as soon as power is restored without interruption or data loss.

5. Partnering with GPower Vietnam in consulting and implementation.

Selecting the appropriate battery pack testing system configuration requires careful consideration of the equipment specifications and the specific needs of each battery pack.

GPower Vietnam is a leading provider of testing equipment solutions and technical consulting services for laboratories in the automotive, battery, and electronics sectors. For the Sinexcel BCTS Series, GPower offers comprehensive support, from needs assessment and voltage/current /power configuration calculations to electrical and heat dissipation infrastructure design, and professional installation, calibration, maintenance, and operational training services.

Refer to the Battery Pack Testing System – BCTS product on the GPower Vietnam website.