GÖPEL electronic GmbH, global industry experts in electrical and optical measurement, testing and inspection technologies, have announced the availability of a new modular battery cell tester for automated safety and functional testing during battery development, incoming inspection and production quality assurance.

High-voltage batteries for e-mobility have become increasingly complex systems incorporating numerous cells, electronics, communications, high-voltage connections and supporting power electronics. Battery cell technologies are also continuing to evolve as manufacturers introduce new cell designs and chemical compositions. These changes require automotive manufacturers and suppliers to establish flexible testing strategies that can accommodate new battery cell requirements in both development and production. GÖPEL electronic developed the new tester as a compact, quickly configurable system designed to support these evolving quality assurance needs.

The modular tester can simultaneously evaluate the quality, charging efficiency and reliability of up to five battery cells. Its multi-cell testing capability allows several cells to be evaluated within the same automated process while helping manufacturers to increase testing throughput. Standard safety and cell-condition testing include open-circuit voltage (OCV) measurement. OCV represents the voltage of a battery cell when no load is connected and serves as an indicator of the cell’s state of charge. The system also performs alternating-current internal resistance (ACIR) measurements to determine the internal resistance of individual battery cells under alternating current. The resulting measurement provides information about cell performance, aging and overall quality. Together, these measurements provide manufacturers with data for evaluating cell condition before individual cells are incorporated into modules and complete battery packs. The results can also support cell grouping, where cells are evaluated and organized before the next stage of battery assembly.

GÖPEL electronic modular battery cell tester for automated OCV and ACIR measurements on up to five cells, featured by EV + Battery Tech Monthly

The modular GÖPEL electronic battery cell tester simultaneously performs automated OCV and ACIR measurements on up to five battery cells

The tester can interface with automated equipment to deliver fast and reproducible batch testing within seconds. This makes the system suitable for incoming inspection, cell grouping and other production quality assurance processes requiring repeated testing of multiple battery cells. The new cell-level system complements GÖPEL electronic’s existing end-of-line battery test equipment for complete battery packs. Those larger systems perform broader safety and functional testing after the cells, battery management electronics, communications, high-voltage connections and cabling have been assembled into the battery module.

Before functional testing begins, the complete battery module undergoes safety testing. Once those tests have been passed, the system can evaluate functions such as the battery communication interface and battery management system. GÖPEL electronic’s pack-level systems use CAN bus communications to control high-voltage switching and check battery status through the battery management system. For modules without a battery management system, cell voltages and temperatures can be monitored using ISO-SPI. A high-voltage power supply that can operate as either a source or sink enables controlled battery charging and discharging. The system can apply a defined charging pulse and verify the battery’s state of charge. Following discharge, energy can be returned to the power grid through the test system.

Additional functional routines can simulate battery safety signals, including checking whether the battery shuts down when a crash signal is received. The system can also confirm whether individual cells can be read through the control unit and whether the battery management system is functioning properly.

Complete test results can be written to a production database for documentation and traceability. Following a successful test, release data can be written through the CAN bus to the battery module’s EEPROM memory. By adding a smaller tester for individual cells, GÖPEL electronic extends its battery quality assurance capabilities to an earlier stage of the manufacturing process. Cells can be evaluated through OCV and ACIR measurements before complete modules and packs undergo more extensive end-of-line safety and functional testing. The new battery cell tester is now available from GÖPEL electronic.

About GÖPEL electronic GmbH

Founded in 1991 and headquartered in Jena, Germany, GÖPEL electronic GmbH develops and manufactures electrical and optical measurement, testing and inspection technologies for electronic components, printed circuit board assemblies, industrial electronics and automotive electronic systems. The company operates through its Automotive Test Solutions, Embedded JTAG Solutions, Industrial Functional Test and Inspection Solutions business units. Its automotive portfolio supports the development, validation and production testing of control units, vehicle networks, infotainment systems, high-voltage applications and e-mobility systems. GÖPEL electronic serves customers through offices and a service network located worldwide. To learn more, please click here.

Source/Photo Credit: GÖPEL electronic GmbH

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Molly Bakewell Chamberlin
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