Battery Module and Pack Testing
The proper tools for the job! REGATRON DC power supplies are ideal for battery testing due to their high precision, flexibility and reliability. It’s an excellent choice for simulating charge and discharge profiles – including
real driving cycles – and for validating battery performance across a wide range of power and technology.
Key Points
- A wide variety of voltage ranges available with auto-ranging of 1:3 each
- High dynamics in the range of 50 – 100 µsec for a step full+ to full- of current
- Ripple modulation up to 10 kHz possible for EIS (impedance spectroscopy)
- Automatic range switching of current measurement for highest resolution
- Real-time charge and energy counter with 48 kHz sample rate
- RPP feature: full protection against wrong polarity and voltage differences device-to-battery
- 60 V – Version with SELV specification available
- Fully regenerative – a real Energy Plus in cyclic operation
Description
Battery testing is essential for evaluating the performance, durability and safety of batteries used in various applications, such as e-mobility, e-aviation, renewable energy storage and industrial systems. Effective testing requires accurate control over charging and discharging cycles, precise monitoring of voltage, current, charge and energy, and the ability to simulate real-world operational conditions. This allows potential problems to be identified, designs to be optimized and industry regulations to be adhered to.
Example of Operation
In electromobility applications in particular, rapid current changes occurring during acceleration and braking should be simulated as realistically as possible in the form of drive cycles. The dynamic characteristics and the current shape of the battery tester unit are therefore of the utmost importance.
The picture on the right shows an example of the convincing step response of the G5.BT series. In addition to the high dynamics, the power supply units also offer adjustment features for the control behavior, e.g. to avoid unwanted current overshoots.
Left: Set for shortest rise time
Right: Set for minimum overshoot of the battery current
Flexibility with Modular Design
Today’s demand for battery power in the field of electromobility and storage ranges from a few kW to the MW range and from a few volts to the 1000+ V range. The modular design of power supply systems offers the advantage that on one hand several channels with lower power can be used to test simultaneously several battery modules, on the other the power modules can be connected to a single channel to test entire battery packs. The ability to connect the battery testers in parallel or in series / matrix gives the operator further flexibility to adapt to ever-changing testing requirements.
Why REGATRON Devices for Battery Testing
REGATRON DC power supplies are an ideal combination of precision, flexibility, safety and efficiency. With their advanced features and customizable profiles, they are best suited for testing a wide range of battery types. Reliability and comprehensive safety precautions ensure reliable and safe test operation. The powerful real-time interfaces CAN or EtherCAT enable tests with a high temporal and electrical resolution. The specialized application software BatControl allows the user to access several test parameter values and even to define complex test procedures. This makes the versatile G5.BT series ideally suited for laboratory tasks and automated test procedures for all types of batteries and energy storage systems.
The built-in G5.RPP feature:
- Reliably prevents damage, sparking and firing caused by accidental reverse polarity connection between battery and battery tester
- Provides overcurrent protection/soft start in case of unmatched voltages between battery and battery tester
- Prevents creeping deep discharge of the battery in the “voltage off” state by means of complete galvanic disconnection of the DUT
Suitable Products
G5.BT Series
Specialized 1- to multi-channel tester / cycler for battery modules and packs, offering adjustable, high dynamics (50…100 µs), outstanding accuracy, and application-specific safety features. It includes a dual measurement range for maximum accuracy and G5.BatControl software. Mobile racks with IP20 or IP54 ratings are available. Optimized for various battery testing applications and EIS.
- Power Range: 0…9 to 0…5000+ kW
- Voltage Range: 0…60 to 0…3000 VDC
G5.UNV Series
Comprehensive solution for testing / simulation of batteries and fuel cells, testing of (solar) inverters and chargers, and P-HIL applications. It incorporates the advanced functions of the specialized G5 series and is designed to meet diverse requirements in an environment of constantly evolving tasks in areas such as product certification, scientific laboratories, R&D, and prototyping.
- Power Range: 0…9 to 0…5000+ kW
- Voltage Range: 0…60 to 0…3000 VDC
TC.GSS Series
Proven and cost-effective, the versatile TC.GSS series includes optional specialized application software, liquid cooling, and ruggedization for harsh / military environments. Engineered for a wide range of applications, including battery module/pack testing, cycling, emulation, low-voltage micro/mild hybrid system testing, and electric driveline component testing.
- Power Range: 0…32 to 0…128+ kW
- Voltage Range: 0…60 to 0…520 VDC
We Are Here to Support You
Experience our commitment to outstanding customer support at every stage — before, during, and after your purchase. Benefit from our complimentary consultation services from the very beginning to ensure the ideal solution for your needs.
For added flexibility, selected power supplies may also be available for rent. Please contact REGATRON to discuss your specific requirements and to check availability for your application.
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