{"id":18847,"date":"2022-02-24T14:39:59","date_gmt":"2022-02-24T14:39:59","guid":{"rendered":"https:\/\/www.innovationnewsnetwork.com\/?p=18847"},"modified":"2022-02-24T14:39:59","modified_gmt":"2022-02-24T14:39:59","slug":"modular-approach-battery-testing-facilities","status":"publish","type":"post","link":"https:\/\/www.innovationnewsnetwork.com\/modular-approach-battery-testing-facilities\/18847\/","title":{"rendered":"A modular approach to battery testing facilities"},"content":{"rendered":"

Chris Garratt of Proventia Oy<\/a> details the intricacies of EV battery testing and how their modular battery testing units can adapt to future needs.<\/h2>\n

In electric vehicles<\/a>, what most people would think of as the \u2018battery\u2019 is called a pack. As the name suggests, the pack is built up from several smaller units called modules. These modules, in turn, are made up of individual cells. The cells are made by a few major suppliers, using various technologies and chemistries. Extensive testing is done on these cells by the companies that make them.<\/p>\n

The end customer or OEM often assembles the modules and packs, and the size and shape will be determined by the application and space available. This means that each module and pack need to be validated to ensure it performs as expected in the environment it will be used in.<\/p>\n

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Fig. 1: Proventia battery chamber layout.<\/figcaption><\/figure>\n

Several aspects need to be tested during the development phase of the modules and packs. Typically, the Battery Management System (BMS) is tested separately using Hardware-in-the-Loop principles, and a reasonably mature BMS is used for physical testing. For physical testing, the aspects outlined below need to be tested.<\/p>\n

Real-world performance simulations<\/h3>\n

Like any engine that goes into a production vehicle, electric powertrains need to be tested on real-world drive cycles. This will ultimately be done as a complete vehicle test on the road, including the motor and inverter. At earlier stages, the real-world performance can be tested using a battery cycler, which can simulate the load that the vehicle\u2019s powertrain would require (the amount of energy drawn by the vehicle to power it down the road). Electric and hybrid vehicles also re-charge the battery under braking, which can also be simulated.<\/p>\n

Charging and discharging performance<\/h3>\n

One of the most contentious issues around electric vehicles is charging, so clearly, this needs to be thoroughly tested. Battery cyclers can simulate a variety of chargers, and it is possible to bring in commercially available chargers to test pack charging.<\/p>\n

Effects of temperature and humidity<\/h3>\n

The environment that vehicles (and their components) need to work in is massively varied. Even in mainland Europe, temperatures can reach over 40\u00b0C, and temperatures can rise much higher inside the vehicle. In Northern Europe, Russia, and North America, temperatures can drop well below -20\u00b0C, and in Asia, humidity can reach above 90%. There are different standards depending on which markets the battery or vehicle manufacturers want to sell into.<\/p>\n

What is required for battery testing?<\/h3>\n

A few vital bits of equipment are needed to perform the necessary tests. As described above, the most critical piece of equipment is the battery cycler, which can charge or discharge the pack and simulate the vehicle\u2019s load. The most important aspects to consider for the cycler are the voltage and current profile it can deliver and the responsiveness of the cycler. The faster it can respond, the more accurately the simulated drive cycles can be recreated.<\/p>\n

An automation and data acquisition system controls the simulation of the drive cycles and monitors the temperatures and communications to the pack under test. This is often split into a regular desktop PC and a real-time operating system for deterministic testing.<\/p>\n

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Fig. 2: Proventia battery test chamber control room.<\/figcaption><\/figure>\n

The Proventia solution<\/h3>\n

Testing prototype battery packs is a potentially risky business, requiring several safety precautions. Whenever carrying out thermal, electrical or mechanical testing of EV batteries, the risk of chemical leaks is of paramount importance. Add to that the risks involved when testing prototypes; a safe solution has to be employed.<\/p>\n

Extensive testing and validation of the battery packs and modules ensure they perform as expected in the environment in which they will be used. Proventia has developed the standard in modular battery pack testing equipment. Proventia\u2019s climatic EV battery testing chambers are designed for both module and complete battery pack requirements.<\/p>\n

Overview of the climatic EV battery pack test chamber<\/h3>\n

Proventia\u2019s climatic EV battery test cells enable real-world performance simulation, charging and discharging performance testing and the effects of temperature and humidity to be tested. The large climatic chamber can be located inside or outside a building and allows full vehicle packs between -40\u00b0C and 90\u00b0C, and 10% to 95% relative humidity, to be tested.<\/p>\n

Proventia\u2018s battery test laboratories conform to the EU Machinery Directive and health and safety regulations, with plans to have a US-ready module by the end of 2022. The modular test cells and centres are fully equipped with modern safety features, including the customer\u2019s preferred fire suppression and facility alarm systems.<\/p>\n

A true turnkey solution<\/h3>\n

As a free integrator, Proventia can combine the high-performance test equipment of the market leaders with the customer\u2019s preferred suppliers. Proventia will integrate the battery cycler, coolant conditioning, automation and data acquisition equipment, as well as any other test equipment needed.<\/p>\n

The Proventia battery pack and module testing unit is a true turnkey solution, including the necessary safety, power, HVAC, plumbing and cabling infrastructure, and complete building management solutions for the test space.<\/p>\n

Standard industrial battery test chambers<\/h3>\n

In addition to customer-specific designs of battery testing solutions, Proventia also offers standardised industrial test modules that fulfil all the industry requirements and are quick to deploy.<\/p>\n

Specifications:<\/strong><\/p>\n