Optimizing the battery cell testing cycle

1. Challenges in testing next-generation battery cells and modules

In the electric vehicle (EV) and battery storage systems (BESS) industries, battery cells and modules are core components that determine the performance, safety, and lifespan of the entire system. To meet stringent research and development (R&D) and quality control (QC) standards, accurate evaluation of electrical characteristics such as capacity, Coulombic efficiency, DC internal resistance (DCIR), and cycle life requires test systems with superior measurement accuracy and instantaneous dynamic response.

The Sinexcel PCDS/BTS Series (Power Battery Cell/Module Testing System) was developed to thoroughly address these challenges. Combining innovative circuit design, high-speed DSP processing algorithms, and advanced semiconductor components (SiC), the system provides a comprehensive solution for optimizing the battery testing cycle.

2. Extremely high measurement accuracy: The foundation for precise analytical data.

One of the leading competitive advantages of the Sinexcel Cell/Module test equipment line is its near-absolute accuracy in both voltage and current measurements.

• - Extremely low measurement error: The device achieves voltage and current accuracy of up to ±0.02% FS (or better than 0.05% FS depending on the rated measurement range). Voltage resolution reaches 0.01mV – 0.1mV and current resolution reaches 0.01mA – 0.1mA.
• - Automatic current switching (Multi-gear current switching): Thanks to its multi-gear current selection feature, the device automatically adjusts to the most suitable measurement range based on the published specifications of the tested battery sample. This maximizes accuracy at both very low and high current levels, minimizing calculation errors when determining DCIR internal resistance or actual capacity.
• - Wide charging/discharging voltage range: Supports charging from 0V to 5V/6V (or customizable up to 10V) for battery cells and from 5V to 60V/150V/300V for battery modules. Discharge voltage can go down to 0V - 1V for cells and 5V for modules, perfectly compatible with many Lithium-ion, Sodium-ion, and new material battery types.

3. Ultra-fast impulse response speed: Realistic simulation of actual operating scenarios.

In real-world operation, electric vehicle battery cells constantly experience sudden changes in current during acceleration, regenerative braking, or uphill climbing. To accurately assess the thermal response and electrical characteristics of the battery, the testing equipment must have extremely fast dynamic response times.

• - Current Response Time (Rise Time): The output current reaches the set value in an extremely short time, only ≤1ms – 2ms (or ≤3ms depending on the model).
• - Switching Time: The transition between charging and discharging occurs instantaneously within ≤3ms – 5ms (or ≤10ms).
• - Real-world driving conditions simulation (Drive Simulation): The device allows direct loading of real-world driving scenarios from Excel files with massive data sets ranging from 3 million to over 10 million lines. The short response time of 10ms – 20ms ensures accurate reproduction of each current/power waveform, supporting pulse tests and high-speed discharge.

4. Flexible interconnected structure and efficient energy regeneration.

In addition to accuracy and response speed, the Sinexcel system also offers many features that optimize operating costs for the lab:

• - Parallel connection for increased capacity: The device supports parallel connection of test channels up to 4800A – 6400A while maintaining current accuracy at ±0.02% FS, effectively meeting the testing requirements for high-discharge battery cells/modules.
• - Green energy regeneration: Energy released during battery discharge is converted and fed back into the grid or directly reused for charging channels with an efficiency of 75% to 92%. Extremely low THD (total harmonic distortion) content (only 3%), minimizing heat generation and significantly reducing operating electricity costs.
• - Peripheral device synchronization: Easily connect to the Battery Management System (BMS), Temperature Chamber, Water Chiller, temperature and pressure sensors. The centralized BTS control software saves data every 10ms, automatically calculates DCIR, generates custom reports, and integrates dual data protection in case of AC power failure.

GPower Vietnam is proud to be a trusted partner and authorized distributor of Sinexcel battery testing solutions. We provide configuration consulting, lab design, technology transfer, and professional warranty and maintenance services to all customers nationwide.

Refer to the testing solutions for battery cells and battery modules.