Energy Regenerative Lithium Battery Automatic Formation and Capacity Grading Testing System

Product Overview

This energy regenerative lithium battery automatic testing formation and capacity grading system delivers high-precision electrical characterization and high-throughput electrochemical conditioning for modern energy storage manufacturing. Engineered with a true four-wire Kelvin measurement configuration and isolated constant current and constant voltage (CC-CV) power stages per channel, this equipment guarantees superior process control across high-volume production and pilot-line validation workflows. By integrating high-efficiency grid-tied energy regeneration, the system converts cell discharge power directly back to the AC grid, drastically slashing factory power consumption, thermal overhead, and operational facility cooling costs.

Designed primarily for lithium-ion pouch, cylindrical, and prismatic cell manufacturing, this platform supports full-lifecycle cell processing ranging from chemical pre-formation and SEI film stabilization to high-accuracy capacity grading, DC internal resistance screening, and sorting. It functions as an indispensable core unit in cell fabrication pilot lines, gigafactory quality assurance stations, advanced research centers, and third-party validation laboratories. The automated architecture interfaces cleanly with barcoding peripherals and Manufacturing Execution Systems (MES) to deliver end-to-end traceability across millions of production cycles.

Built on a rigid industrial frame with heavy-duty thermal isolation and continuous 24/7 hardware monitoring, the equipment maintains precision integrity across extended production campaigns. A fully digitized calibration architecture minimizes annual drift, maintaining rigorous accuracy across long operating intervals. Combined with comprehensive hardware-level and software-level fault response matrices, the unit ensures unmatched operator safety, cell protection, and non-stop operational availability under continuous industrial loading.

Key Features

• Energy-Regenerative Power Topology: Advanced bi-directional power conversion architecture captures battery discharge energy and feeds it directly back into the three-phase AC facility grid with a discharge recovery efficiency of ≥65% and a charging output efficiency of ≥70%, significantly reducing factory utility bills and HVAC thermal loading.
• Independent 128-Channel Modular Control: Configured with 128 completely isolated electrical channels, each driven by its own independent constant-current and constant-voltage source to ensure zero crosstalk, complete loop isolation, and hot-swappable modular field servicing.
• High-Precision Four-Wire Kelvin Sensing: Four-wire Kelvin measurement leads eliminate lead-wire resistance and contact potential drops, securing exceptional voltage measurement accuracy of ±(0.05% FS + 0.05% RD) and current accuracy of ±(0.05% FS + 0.05% RD) with 0.1 mV and 1 mA resolution.
• Rapid Whole-Cabinet Polling Architecture: High-speed internal acquisition circuitry scans and records telemetry across all 128 channels in ≤3 seconds per cycle, capturing dynamic voltage inflection points, instantaneous current steps, and transient capacity transitions in real time.
• Multi-Paradigm Capacity Grading Algorithms: The control software supports diverse sorting modes including pure capacity grading, step-time grading, capacity combined with curve fitting, time combined with curve matching, capacity plus voltage thresholds, and fixed-point voltage differentiation to classify cell performance groups precisely.
• Comprehensive Multi-Tiered Safety Matrix: Hardware-level and software-level dual protection loops continuously guard against over-voltage, under-voltage, over-current, under-current, capacity overflow, and leakage currents, instantly isolating affected channels while maintaining safe operation across adjacent positions.
• Full Traceability and Barcode Integration: The system supports wireless 1D/2D optical barcode scanning with sequential and channel-skip binding modes, matching every individual cell serial number to its designated channel data and storing records in an MES-ready standard database format.
• Robust Data Resiliency and Power-Loss Recovery: Built-in hardware memory registers and transactional database storage provide complete power-outage protection, allowing automated process resumption from the exact interruption point without data loss or cell over-processing.
• Centralized Distributed Supervisory Control: A single host PC workstation efficiently orchestrates, programs, and monitors up to 20 networked formation cabinets over industrial RS485 buses, supporting complex 32-step recipes and up to 256 nested loop cycles per workflow.

Applications

Technical Specifications

Why Choose This Product

• Industrial Grade Measurement Accuracy: Engineered with an industry-leading ±(0.05% FS + 0.05% RD) measurement baseline across both voltage and current channels, this system eliminates electrical noise and thermal drift, guaranteeing reproducible capacity sorting and formation consistency.
• Substantial Energy and Operating Cost Reductions: The integrated energy-regenerative power module recycles discharge energy back into the plant power grid with up to 65% recovery efficiency, dramatically lowering electricity overhead while decreasing cooling requirements within high-density cleanroom facilities.
• Enterprise MES and Traceability Integration: With native support for 1D/2D scanning, standardized MDB output files, and automated database sync routines, the equipment links seamlessly into factory-level MES platforms to achieve complete batch validation and compliance audits.
• High Reliability with Low Maintenance Overhead: Featuring modular channel cards, non-interfering isolated circuits, digital software calibration, and hardware-level interlocks, this unit delivers uninterrupted 24/7 reliability in demanding manufacturing environments.

Contact our technical sales team today to request a quotation or discuss customized formation and grading configurations tailored to your cell chemistry and production throughput requirements.

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