Battery Tester
Automated Clamping Battery Formation and Capacity Grading Cabinet for Cell Inspection and Sorting
Item Number : CD05
Price varies based on specs and customizations
- Channel Configuration & Current
- 128 Channels, 300 mA to 30,000 mA (30 A) per Channel
- Measurement Accuracy
- Voltage & Current: ±0.05% FS + 0.05% RD (Four-Wire Kelvin Sensing)
- Energy Recovery & Power Efficiency
- Discharge Grid Feedback ≥ 65%, Charge Efficiency ≥ 70%, Max Power ≤ 23 kW
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Product Overview
This high-throughput battery formation and capacity grading cabinet is an industrial-grade testing platform engineered for automated secondary cell production and rigorous quality assurance. Designed with an integrated automated press-down clamping mechanism and double-sided battery placement, the equipment streamlines cell loading and connection routines across 128 independent channels. Each channel incorporates a dedicated constant-current and constant-voltage source, ensuring zero cross-channel interference and delivering uncompromised measurement integrity during continuous charge, discharge, and resting cycles.
Engineered specifically for pilot lines, commercial manufacturing plants, and high-volume quality inspection facilities, this system accommodates a wide spectrum of prismatic, pouch, or custom cylindrical cells. Its dual-sided layout maximizes footprint utilization while maintaining rapid inspection scanning intervals of 3 seconds or less across the entire cabinet. The integrated software platform provides full MES connectivity, multidimensional curve rendering, dynamic sorting algorithms, and barcode traceability, making it an essential asset for advanced battery production lines and cell research centers.
Built to withstand rigorous continuous operation, the system features heavy-duty structural framing, energy-recovery power architecture, and dual-layer hardware/software fail-safes. The precision instrumentation maintains high accuracy across extended six-month calibration intervals, minimizing operational downtime. By combining automated pneumatic/electric clamping mechanics with high-precision four-wire Kelvin sensing, this equipment provides dependable consistency, high operational safety, and repeatability under high-load industrial conditions.
Key Features
- Automated Electric Press-Down Clamping: The mechanized top-down clamping assembly automatically secures multi-pin test fixtures onto cell terminals simultaneously, standardizing contact pressure, eliminating manual clamping errors, and drastically reducing batch loading cycle times.
- True Four-Wire Multi-Pin Kelvin Sensing: Independent voltage and current leads extend directly to the contact probe tips, eliminating contact resistance and lead impedance to achieve ±0.05% FS + 0.05% RD measurement accuracy across full operating ranges.
- 128 Independent Testing Channels: Every channel operates on a completely isolated constant-current and constant-voltage power loop, preventing mutual cross-talk and allowing flexible execution of varied testing protocols across channels.
- Energy-Regenerative Power Architecture: Built-in high-efficiency power electronics feed discharge energy directly back into the AC grid with up to 65% recovery efficiency, substantially reducing facility thermal loads and power consumption.
- Comprehensive Multi-Parameter Sorting Methods: The system supports versatile capacity grading rules, including standard capacity, process time, capacity plus dynamic curve matching, time plus curve matching, and setpoint voltage grading.
- High-Speed Real-Time Channel Polling: Complete cabinet scanning of all 128 channels updates in 3 seconds or less, ensuring rapid data acquisition, responsive safety limit triggering, and high-resolution transient curve generation.
- Dynamic Real-Time Curve Diagnostics: The supervisory software renders real-time voltage-time, current-time, capacity-time, energy-time, and capacity-voltage curves, providing complete diagnostic visibility into internal electrochemical behavior.
- Intelligent Barcode Binding and MES Integration: Integrated optical barcode reading supports 1D and 2D codes with sequential or channel-skip scanning, automatically binding cell serial numbers to channel test data for complete traceability via standard database export.
- Multi-Tier Hardware and Software Safety Protection: Comprehensive fail-safes continuously monitor for over-current, under-current, over-voltage, under-voltage, over-capacity, and leakage current, featuring hardware-level hard-stop cutoffs on critical limits.
- Data Power-Loss Recovery Protection: Embedded non-volatile memory registers preserve operational parameters and step progress during sudden electrical outages, automatically resuming workflows upon power restoration without data corruption.
Applications
| Application | Description | Key Benefit |
|---|---|---|
| Prismatic Lithium-Ion Cell Formation | Initial solid electrolyte interphase (SEI) layer formation via controlled CC/CV charging across high-capacity prismatic cells. | Uniform SEI formation with precise current stepping and micro-level voltage monitoring. |
| Commercial Battery Capacity Grading | High-throughput discharge testing to classify manufactured cells into tightly binned capacity and voltage tolerance groups. | Eliminates capacity mismatch in downstream pack assembly through multi-parameter grading curves. |
| Battery Pack Production QC Inspection | End-of-line verification testing of incoming cells to detect internal micro-shorts, abnormal self-discharge, and high contact impedance. | Fast screening and sorting via 3-second cabinet polling and integrated barcode traceability. |
| Life Cycle and Degradation Profiling | Multi-cycle endurance evaluation executing up to 256 programmable loops to analyze capacity fade and Coulombic efficiency. | Reliable long-term unattended operation with 6-month calibration stability and automated data logging. |
| Pilot-Line R&D Electrochemical Testing | Rapid prototyping of novel cathode/anode formulations and electrolyte additives under diverse C-rate charging profiles. | Independent channel control allows parallel execution of differing test profiles across one cabinet. |
| Energy Storage Cell Pre-Shipment Validation | High-current charge-discharge cycling (up to 30 A per channel) for commercial ESS cells prior to modular integration. | Reduced operational electricity expenses via 65% discharge grid-tie energy regeneration. |
| Post-Formation Aging and Self-Discharge Analysis | Precise open-circuit voltage (OCV) and resting platform tracking following formation to identify defective cells. | High-resolution voltage sensing (0.1 mV) identifies subtle electrochemical self-discharge anomalies. |
Technical Specifications
| Specification Parameter | Value / Characteristic |
|---|---|
| Product Item Identifier | CD05 |
| Channel Capacity | 128 Independent Channels (Double-Sided Layout) |
| Fixture Mechanism | Automated Electric Press-Down Multi-Pin Clamping |
| Fixture Measurement Type | True Four-Wire (Kelvin Connection), Adjustable Polarity Spacing |
| Charge / Discharge Current Range | 300 mA to 30,000 mA (30 A) per Channel |
| Current Measurement Accuracy | ±0.05% FS + 0.05% RD |
| Current Resolution | 1 mA |
| Voltage Measurement Range | 0 mV to 5000 mV (0 to 5 V) |
| Charge Voltage Range | 0 mV to 4500 mV (0 to 4.5 V) |
| Discharge Voltage Range | 800 mV to 4500 mV (0.8 to 4.5 V) |
| Voltage Measurement Accuracy | ±0.05% FS + 0.05% RD |
| Voltage Resolution | 0.1 mV |
| Time Measurement Range & Accuracy | Up to 999 minutes per step, Accuracy: ±0.1% |
| Calibration Method & Stability Cycle | Software digital calibration; ≥6 months stability within specification |
| Programmable Step Types | Constant Current (CC) Charge, CC-CV Charge, CC Discharge, Rest/Dwell |
| Step Termination Conditions | Current, Voltage, Time, Capacity |
| Max Step & Cycle Capability | Up to 32 Steps per recipe; Up to 256 Execution Cycles |
| Full Cabinet Inspection Polling Speed | ≤ 3.0 Seconds (all 128 channels) |
| Capacity Grading Modes | Capacity, Time, Capacity + Curve, Time + Curve, Capacity + Voltage, Setpoint Voltage |
| Safety Protections | Over-Current, Under-Current, Over-Voltage, Under-Voltage, Over-Capacity, Leakage Current; Dual Hardware & Software Protection for Over-Voltage / Under-Voltage |
| Display & Diagnostic Curves | Real-time I-t, V-t, C-t, E-t, and C-V dynamic graphical curves |
| Data Acquisition & Export | Local raw/result data logging (MDB database format), MES server export compatibility |
| Barcode Scanning Capability | Supports 1D / 2D barcode scanning with channel binding and sequential/skip modes |
| Host Computer Capacity | 1 Host PC controls 1 to 20 Cabinets (Recommended: 10 Cabinets per PC) |
| Host Interface / Communication | RS485 Serial Network Protocol |
| Operating Software Platform | Windows-based control suite with recipe library and status LED drivers |
| Power Conversion Efficiency | Charge efficiency ≥ 70%; Grid-feedback discharge recovery efficiency ≥ 65% |
| Overall Power Consumption | ≤ 23.0 kW |
| Fixture Spacing (Positive to Negative) | Compatible Range: 45 mm (Min) to 150 mm (Max) |
| Compatible Cell Height Range | 50 mm to 220 mm |
| Fixture Center-to-Center Pitch | 78.5 mm |
| Tray Shelf Layer Pitch | 270 mm |
| Tray Elevation Range | Lowest Layer: 270 mm; Highest Layer: 1620 mm |
| External Dimensions (L × W × H) | 2030 mm × 700 mm × 2020 mm |
| Input Power Supply Requirements | Three-Phase AC 380V ± 10%, 50 Hz |
Why Choose This Product
- Superior Channel Independence and Accuracy: Featuring 128 dedicated constant-current and constant-voltage hardware sources coupled with true four-wire Kelvin sensing, this equipment prevents cross-channel interference and guarantees laboratory-grade precision across heavy production cycles.
- High-Throughput Automated Ergonomics: The dual-sided design with automated electric top-down clamping drastically decreases operator fatigue, eliminates manual cabling bottlenecks, and maximizes cell testing density per square meter of facility floor space.
- Substantial Energy and Operating Cost Savings: Integrated regenerative grid-feedback power supplies recycle up to 65% of discharged electrical energy back to your facility grid, sharply cutting utility bills and reducing HVAC cooling loads.
- Full Traceability and Industrial MES Compatibility: Standardized database architecture and barcode scanning directly connect cell identities with granular formation curves, ensuring compliance with automotive-grade quality audits and battery passport tracking.
- Long-Term Operational Stability: Built with premium industrial electronics and robust mechanical actuators, this platform maintains rigorous calibration accuracy for over six months, backed by comprehensive engineering support and tailored customization.
Contact our technical sales team today to discuss your cell dimensions, request a formal quote, or configure a customized automated formation and grading solution for your facility.
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