Automated EV Battery Interconnect Tester – Stingray
- Category: Flying Probe Testers
- Manufacturer: Acculogic
The Fast & Cost-Effective Way to Test Electric Vehicle Batteries
Accurate testing of battery cell interconnects is critical to confirming the presence of solid bonds between battery cells. Automated interconnect testing minimizes the chance of vehicle failures resulting from faulty batteries before vehicles leave the production line.
About the Automated EV Battery Interconnect Tester – Stingray
Until NOW, Battery Interconnect Testing Was Slow & Expensive - The Stingray Automated EV Battery Interconnect Tester Changes That!
Battery lifetime and stability play essential roles in developing next-generation electric cars. An electric car is driven by one or more electric motors, using energy stored in rechargeable batteries. A significant safety concern arises from the technical challenges around battery lifetime.
Manufacturing large numbers of battery modules/packs require in-process automated electrical testing to ensure high production yield. Accurate testing of battery cell interconnects is critical to confirming the presence of solid bonds between battery cells. Automated interconnect testing minimizes the chance of vehicle failures resulting from faulty batteries before vehicles leave the production line.
EV BATTERY MODULES
Battery modules contain hundreds to thousands of battery cells interconnected to store and discharge energy. Each cell has two interconnects that need electrical testing to ensure the battery module performs to specification. These connections are crucial to managing the current flow between each cell and delivering sufficient energy to the powertrain. High resistance bonds can lead to excessive heat generation when current passes through them. Likewise, should several of these connections break within a pack, the required current will be drawn from a smaller number of cells leading to overheating and, in the worst cases, even fire.
ONE TESTER FOR MULTIPLE BATTERY CONFIGURATIONS
Test different battery module configurations with the same tester depending on the number & type of Probe Modules installed.
TEST METHOD
The fixed grid pattern of batteries in a battery module permits the use of a test head containing several contact pins. The test head travels over the grid and lands on the battery module, making contact with test points. This makes it possible to quickly test the interconnectivity between multiple battery cells.
A safety contact pin contacts the same surface. The resistance between the test head contact pins and the safety contact pin is measured. The measurement taken indicates the quality of the wire bond.
The measuring quality can be significantly increased at each connection measurement by measuring the pin contact quality. It is also possible to test battery modules that use plates as bus bars under which the associated battery electrodes are located with holes arranged in a grid-like pattern. Here the contact pins are arranged and constructed to reach through the holes to precisely contact the battery electrodes from the free side of the plate-shaped bus bar.