Cylindrical Cell Toggle Clamp Test Fixture for Large Format Battery Testing

Product Overview

This cylindrical cell toggle clamp test fixture is a high-performance electrical testing apparatus engineered specifically for large-format cylindrical cells such as the 60140 format. Designed to meet the stringent demands of advanced battery research, pilot-scale cell characterization, and high-rate electrochemical testing, this fixture combines robust mechanical toggle clamping with low-resistance current collectors to establish rapid, repeatable, and ultra-reliable electrical contact.

Built to accommodate continuous current loads up to 100A with minimal thermal dissipation, the equipment serves battery research laboratories, electric vehicle powertrain development facilities, grid-scale energy storage pilot lines, and industrial quality assurance departments. Its high-precision mechanical guidance ensures uniform axial compression across cell terminals, eliminating contact variability and protecting sensitive cell pole structures during high-volume testing.

Constructed from premium industrial insulating materials and high-strength metallic structural components, this fixture guarantees exceptional structural rigidity and long-term dimensional stability. Whether deployed for DC internal resistance (DCIR) measurement, high-rate charge-discharge cycling, or automated cell grading, the system maintains consistent contact impedance below 0.2 milliohms across thousands of consecutive test cycles under demanding laboratory and industrial conditions.

Key Features

• High-Current Toggle Clamping Kinematics: The integrated industrial toggle clamp mechanism enables rapid single-motion cell insertion and clamping, applying consistent axial force through a movable current pin while holding the opposing pin stationary for maximum mechanical repeatability.
• True Four-Wire Kelvin Sensing Architecture: Independent current excitation and voltage sensing paths decouple contact resistance from measurement circuits, delivering pristine voltage signal acquisition for micro-ohm level DCIR and AC impedance characterization.
• Heavy-Duty Low-Resistance Current Probes: Featuring massive current probes with diameters exceeding 12 mm fabricated from premium phosphor bronze and beryllium copper, the fixture delivers over 4 kg of contact force at 5 mm compression to minimize interface resistance.
• Dedicated Spring-Loaded Voltage Pins: Centralized phosphor bronze voltage sensing probes with a sub-2 mm outer profile exert an independent 200 g contact force at 2 mm compression, ensuring direct, non-invasive terminal surface voltage tracking.
• Precision 60140 Cell Center Alignment: An integrated center positioning block guides 60140 cylindrical cells into exact coaxial alignment with terminal contact pins, ensuring repeatable engagement with 8 mm flat and smooth cell poles.
• Sub-15°C Thermal Rise at 100A Continuous Load: Superior contact cross-sections and optimized current paths restrict fixture temperature rise to less than 15°C during continuous 100A testing, preventing thermally induced measurement drift and cell heating.
• Heavy-Duty Gold-Plated Probe Surfaces: Probes feature heavy gold plating exceeding 4 mil to resist galvanic corrosion, minimize surface oxidation, and maintain stable contact interface resistance over extended cycling intervals.
• Rigid Insulated Base with M10 Terminal Connections: The composite non-conductive fixture base integrates heavy-duty M10 terminal lugs for direct connection to heavy-gauge battery cycler cables, secured via dedicated benchtop screw mounting points.

Applications

Technical Specifications

Why Choose This Product

• Engineered for High-Current Integrity: Unlike standard testing clips prone to overheating, this fixture is purpose-built to sustain 100A continuous current with less than 15°C temperature rise, maintaining safety and data accuracy.
• Precision Clamping Repeatability: The mechanical toggle linkage combined with spring-loaded beryllium copper current probes applies a calibrated force exceeding 4 kg, eliminating operator-dependent contact variance across shifts.
• Dedicated Large-Format Cell Optimization: Custom-machined for 60140 cylindrical cells with 8 mm poles, the integrated center stop ensures instantaneous, self-aligning cell placement for rapid throughput.
• Superior Corrosion Resistance and Longevity: Thick gold plating (> 4 mil) across high-wear contact surfaces prevents oxidation and fretting wear, ensuring consistent sub-0.2 mΩ contact resistance over years of daily operation.
• Modular and Robust Benchtop Integration: The rigid dielectric frame and heavy-duty M10 terminals allow secure benchtop screw mounting, integrating cleanly into laboratory test benches and environmental chambers.

Contact our technical sales team today to request a quote or discuss custom fixture adaptations for your specialized battery testing requirements.

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