rom initial cell development to end-of- line validation, battery testing is a critical step in delivering performance,
reliability and safety. However, in parallel with advancements in battery technologies and applications, the need for robust and precise testing equipment has grown more urgent, with the need for more rigorous and comprehensive testing protocols essential. In the EV sector, the push for longer range,
faster charging and improved safety has led to the adoption of new chemistries and cell designs. Each of these innovations necessitates thorough testing to validate performance, ensure consistency, and prevent defects. Similarly, the growth of stationary storage demands reliable battery systems with long lifespans and stable performance. Testing equipment plays a vital role in characterising cells, modules and packs to confirm they meet required specifications for capacity, efficiency, thermal behaviour and durability.
To help with this, automated high throughput testing systems are being used. Manufacturers conducting battery testing typically begin by procuring essential core products, primarily the power supplies needed to source or sink energy. These power supplies are critical for simulating real-world operating conditions. Once acquired, these components are
integrated into larger, more complex, testing systems by the battery OEM. This allows the testing setup to adapt to evolving battery designs and increasingly stringent performance requirements, ensuring that test protocols remain aligned with innovation in battery technology. A key innovation in this space is the adoption of
bidirectional power supplies. Unlike conventional setups that rely on separate power supplies to charge and discharge a battery, bidirectional units perform both functions through a single connection. This dual-role capability streamlines the testing process and allows regenerative energy to be fed back into the grid. “Bidirectional power supplies deliver power to
the device under test and simultaneously function as electronic loads by absorbing energy,” explains Andrew Engler of Intepro Systems. “This dual capability enables seamless transitions between charging and discharging cycles, making them ideal for advanced battery testing.” With power ranges typically starting at one
kilowatt and extending to hundreds of kilowatts, bidirectional systems support virtually every stage of EV battery production – from initial cell validation to full pack testing – as well as the testing of EV charging stations.
High-power battery pack testing typically refers to testing scenarios involving battery systems that deliver or absorb between 50 kilowatts to several hundred kilowatts of power, although this can exceed one megawatt. This type of testing is essential for applications including electric vehicles, large electric trucks and buses, energy storage systems, aerospace platforms, emerging electric propulsion technologies used in electric vertical takeoff and landing aircraft or unmanned aerial vehicles, and electric rail and marine propulsion systems. Emerging solutions include the Cinergia line, which supports high-power battery pack testing at power levels exceeding 60 kilowatts. Cinergia Power Solutions, headquartered in Barcelona, specialises in regenerative and programmable power converters (distributed in North America by Intepro Systems). Cinergia’s bidirectional power supplies deliver
both AC and DC output from a single unit, a design which offers both cost savings and operational flexibility in EV applications. Engler adds: “For example, a single unit can cover testing for batteries, motors and charging stations, eliminating the need for separate equipment for each function.” “If test requirements shift between AC and DC,
the system accommodates that change without requiring additional hardware,” adds Engler. Available in models ranging from 7.5 kW
to 160 kW, the Cinergia bidirectional power supplies support both 2-quadrant and 4-quadrant operations. Multiple units can be connected in parallel to increase total power output, and configurations can be tailored to specific testing requirements. “A single rack can deliver up to 200 kilowatts, and up to eight racks can be paralleled. “This configuration enables testing of batteries up to one megawatt in capacity, with scalability beyond that, if needed,” says Engler. Each unit is equipped with three independent outputs, enabling simultaneous testing of up to three batteries at different power levels. The Cinergia line also includes regenerative
capabilities that allow excess energy to be fed back into the grid, promoting energy conservation. With a Total Harmonic Distortion
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Automated testing systems now use bidirectional power supplies that combine charging and discharging in one unit.
(THDi) of less than 3% and a Power Factor (PF) exceeding 0.98, the B2C+ ensures minimal impact on the power grid, maintaining high-quality power standards. By seamlessly
switching between sourcing and sinking modes, these
supplies enable precise control of current and voltage without the need for external switching hardware or additional load banks. The regenerative function
contributes to significant energy savings and reduced heat buildup in the test environment, minimising cooling requirements and overall operating costs.
Lower power battery pack testing involves
systems that typically operate below 50 kilowatts, often found in smaller consumer electric vehicles, such as electric scooters, e-bikes, and compact passenger vehicles and residential energy storage units. Portable power stations, medical devices and industrial handheld tools similarly undergo low-power testing. Delta Elektronika’s DC power systems are
suitable for lower power applications. Delta systems use a 15-kilowatt building block that supports a broad range of applications and can be scaled by connecting up to 20 units. The units combine fast dynamic response, low output noise, and extremely long product lifespans. The bidirectional power supplies also
feature regenerative functionality, enabling them to return energy to the grid with efficiencies reaching up to 95%, significantly reducing energy waste compared to systems that dissipate excess energy as heat. These systems also provide significant advantages in both cost and lead times, with a typical turnaround ranging from two to four weeks.
The development of bidirectional power supplies represents a major shift in battery testing practices. These systems enable smooth transitions between charge and discharge modes, support both AC and DC operation, and incorporate regenerative features that reduce energy consumption and lower overall operating costs.
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