Engineers also check for any malfunction, temperature rise in the battery pack, current carrying capacity, cooling capacity, and overall mechanical structure. After complete testing, packs may undergo extra testing to simulate the typical conditions and be integrated into the system or end-product.
Additionally, other tests like thermal abuse, mechanical vibration, high-voltage protection, and environmental tests are carried out at this level to ensure voltages are accurate and safe, temperature sensors function effectively, and cells are well balanced. Pack level testing is sometimes also called End-of-Line Testing or Assembly Testing.
“Test stand drives with accurate application parameters can reduce operating costs, testing time and mitigate safety risks” Battery Module and Pack tests typically evaluate the battery performance, safety mechanisms, cooling systems, and internal heating characteristics.
If the strings of modules within the pack show irregularities in the expected voltage, resistance or capacity range, it can be found here and rectified. Engineers also check for any malfunction, temperature rise in the battery pack, current carrying capacity, cooling capacity, and overall mechanical structure.
Also measure the resistance of the bus bars of the battery stack safely. Safely measure the voltage and internal resistance of high-voltage stacked battery packs with a dedicated probe. The BT3564 is a battery tester for simultaneous measurement of internal resistance and battery voltage with a maximum input voltage of 1000 V.
Standard tests include drive-cycles, peak power capability, BMS software validation, and application-specific characterization tests. The goal of testing batteries as an individual component or subsystem is to answer specific questions about the design or build. For example, how will the battery perform at different temperature levels?