Once an automaker completes battery cell selection, battery design, and development, it then faces cost and speed bottlenecks during mass production. EV battery production safety must be taken seriously, as the process involves the potential hazards of high voltage and high energy density. Using an automated battery inspection system can effectively reduce production costs and improve performance, while also ensuring the safety of the entire manufacturing process. Furthermore, manual testing can lead to inconsistent results, errors in handwritten data, lengthy testing times, product traceability issues, and more. Currently, automakers require End-of-Life (EOL) testing for finished battery packs before shipment, lasting 10–20 minutes per unit, with real-time monitoring, automatic traceability reporting, and safety protection mechanisms. Therefore, modular and automated testing solutions have been gradually adopted by many automakers for battery production.
The testing functions applied by the automated end-of-life (EOL) lithium battery testing system encompass mechanical assembly, high-voltage insulation, battery management system (BMS) communication, internal on/off switches, battery imbalance, and temperature distribution, among others. It can be used not only on the production line but also for R&D near the completion stage or for battery power inspection. Automated testing prevents unnecessary personnel work and ensures operator safety, making it applicable to battery modules for electric cars, electric motorcycles, and energy storage systems. The main features and specifications of the Chroma automated battery testing system are listed below:
• For the production of battery modules or the use of R&D unit testing verification.
• Improve the efficiency of product inspection.
• Battery module tests for BMS function / resistive voltage connector / consistency / performance.
• Charging and discharging power range: 5kW ~ 500kW.
• Power range / charging and discharging current: 0V ~ 1200V / 0A ~ 2600A.
• Standard test items include: Insulation test, electrical test, software/communication test, and battery function test.
• Capable of providing the necessary accessories to connect the battery modules with the automatic control switching function.
The automated end-of-life (EOL) lithium battery test system can be integrated with Chroma electrical safety analyzers, switching devices, digital meters, and regenerative charge/discharge systems via an open software platform for diverse testing applications. Supported by Shop-Floor programs and MES interconnects, data ingestion and monitoring are easily integrated. The test system can also handle various automated production line requirements for PLCs, MES, and safety mechanisms, providing a more comprehensive, customized automated test station.
