Battery Testing in R&D

Solutions for Battery Development, Testing and Validation

In response to the growing need for precise development and validation of high-performance batteries and hybrid systems, HORIBA offers the Battery Evaluator, a solution tailored to meet the demanding requirements of battery development and testing with high accuracy and adaptability.

The Battery Evaluator B series is optimized for testing batteries of various technologies and can be tailored to suit your specific testing needs and applications, thanks to its modular design and advanced safety features.

Our comprehensive solutions integrate a diverse array of equipment and technologies, facilitating centralized, user-friendly preparation, execution, and evaluation of complex tests. Whether analyzing durability and capacity under diverse environmental conditions or assessing battery degradation and driving cycles, our Battery Evaluator ensures precise and reliable results.

Highlights

  • Customized X‑HVT charge-discharge units with up to 1500 A / 1500 V / 1000 kW
  • Integration of climate chambers, chillers and other customer devices
  • Full flexibility with powerful STARS software
  • Outstanding accuracy and resolution for R&D application
Example setup for R&D Battery Testing

Tailored to meet your requirements

The R&D battery test stand may include the following elements:

  1. DC supply (X-HVT charge and discharge unit):
    Up to 1000 kW / 1500 V / 1500 A
  2. Power cabinet:
    Distribution of needed voltage and power supply for BMS (Battery Management System)
  3. Control cabinet:
    With fail-safe PLC control, connection to the automation system
  4. DAQ: data acquisition:
    Temperature, voltage, current; with EtherCAT support
  5. Thermal or climate chamber:
    Different sizes, indoor/outdoor and container installations possible
  6. Temperature control module:
    Up to -40°C (-40°F) and +90°C (+194°F) with accuracy up to 0.05K
  7. Operators' desk, automation system (not shown in visualization):
    With STARS Automation system
     

► Contact us now for individual consultation and a customized offer!

Facts and Specifications: Evaluator B

Solutions for Battery Development, Testing and Validation

Integration

  • Overall safety concept with event handling
  • Fail safe PLC control
     

Software & Automation

  • STARS Automation
  • Unattended 24/7 operation
  • Real time system
  • Remote interface
     

Data Logging

  • Central data handling with sampling rates up to 1 ms
  • Flexible data log configurations
  • Flexible data export

Current

  • Up to 1500 A
  • High dynamic current slew rates
     

Voltage

  • Up to 1500 V
  • 4 quadrants operation with 0 V option
     

Power

  • Up to 1000 kW & overload of 30 to 50 %
  • Grid feedback, up to 95 % efficiency
  • Multi-Channel configuration with load management
     

Impedance

  • Integrated measurement under load up to 500 A / 100 kHz

Execution

  • Mobile
  • measure gallow
  • control cabinet
     

Connectivity

  • Measuring of temperature, voltage, current
  • Different accuracy, measuring range and measurement data acquisition rates with EtherCAT support
  • Control functions via analog and digital in- and output
     

CAN Gateway

  • Test item interface with real time CAN interface and terminal control

Environmental Simulation

  • Thermal or climate chamber according to EUCAR Hazard levels
  • Out/Indoor container installations
     

Safety Features

  • High Voltage protection concept and touch proof design
  • Door monitoring and close mechanism
  • Exhaust gas handling and monitoring
  • Inerting systems and firefighting systems
     

Chiller

  • Battery cooling systems in different configurations for multiple channels and medias

Performance Tests

  • Capacity test
  • Internal resistance and pulse power test
  • Adjusting the SOC (state of charge)
  • Lifecycle and endurance test for accelerated aging
  • Driving cycle test
     

Environmental Simulation

  • Temperature shock test
  • Humidity and corrosion test
  • Dust test
  • Vibration and shock test

CE Conformity Marking (according to)

  • EMC directive 2014/30/EC
  • Low voltage directive 2014/35/EC
  • ATEX directive 2014/34/EC
  • General product safety directive 2001/95/EC
  • Machinery directive 2006/42/EC
  • Pressure equipment directive 2014/68/ EC
     

Risk Assessment

  • DIN EN ISO 13849
  • DIN EN ISO 1210

Facts and Specifications: X-HVT

Charge-Discharge Unit for High Voltage Emulation

Power Rating

  • 60 kW, 160 kW, 250 kW, 300 kW, 600 kW, 900 kW 1000 kW
  • further types on request
     

Overall Efficiency at Power Rating

  • ≥ 95 %
     

Noise

  • ≤ 70 dB (A) at 1 m (160 kW, 600 A)

Operating Modes

  • CC, CV, CP, CCMOD
     

Voltage Range

  • 800 V, 1000 V, 1200 V, 1500 V
  • further types on request
     

Current Range

  • ±600 A, 800 A, ±1000 A, ±1200 A, 1400 A, 2000 A
  • further types on request
     

Measurement Accuracy

  • ±0.03 % MV, ±0.015 % FS
     

Resolution

  • 16 bit
     

Sampling Rate

  • 10 µs (100 kHz)
     

Storage Rate

  • 3.0 ms

Cycle Time

  • 3 ms
     

Standard Models

  • VOCV + R1 + R2 || C1
  • VOCV + R1 + R2 || C1 + R3 || C2
  • VOCV + R1 + R2 || C1 + R3 || C2 || R4
     

Setpoint

  • Voltage
  • SOC
     

Parameter

  • Rated capacity
  • Open circuit voltage
  • Technology (SOC curve)
  • Internal resistance
  • Dynamic (resistance and capacity)
  • Temperature (optional)

Frequency Range

  • 0.1 mHz to 10 kHz (optional up to 50 kHz)
     

Impedance Range

  • 5 µΩ up to 100 Ω
     

Impedance Accuracy

  • ±1 %, ±100 µΩ
     

Phase Angle Accuracy

  • ±1 °
     

Max. Modulation Current

  • ±10 AAC

Ripple

  • < 0.1 % eff. FS
     

Risk Assessment

  • < 3 ms

Safety Controllers

  • Emergency stop (two channels)
  • DC-Stop (two channels)
  • DC-On (two channels)
  • Signal of ISO-controller
     

ISO Controller

  • Insulation resistance HV Plus and HV Minus
  • Analog processing of insulation resistance
  • Safe disconnection of DC contactors
     

Safety Version according to ISO 13849 / EN 60204-1

  • Galvanically isolated IGBT half bridges
     

Verification of the functional safety (audit trail) incl. creation of validation certificate ISO 13849

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Make sure you don't miss our live webinar on Battery Testing Solutions on July 3rd, 2024
► Register now! ◄

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