Battery Testing

The controller, specially developed for battery tests, enables tests with the highest dynamics and accuracy while complying with the charge-discharge limits of the device under test.

With the use of a ripple generator, signals with up to 15 kHz can be modulated in order to simulate inverter feedback effects, for example.

A pre-charge regime enables the current-free connection of a battery.

Additional measurement ranges for current and voltage provide more flexibility and accuracy.

The ESYS can also be used as a battery simulator for powertrain applications. Therefore, it contains several electrical battery models (e.g. R, RC).

Key Benefits of ZF TS esys

• Regenerative DC voltage sources
• SiC power electronics for efficient and compact design
• Higher power direct parallel connect-ability
• Power in the loop with Inverter/ DCU setup
• Control loop and switching frequency 400 kHz
• Ripple simulation 0.01 Hz to 15 kHz
• Turn-key battery testing solutions:
  - Cell, Module, and Pack Testing
  - End-of-Line Testing
  - Lifecycle & Endurance Testing
  - Vibration Testing
  - Abuse Testing

The expertise includes Performance & Endurance Testing, Environmental Testing and Mechanical & Abuse Testing. All types of batteries can be tested - from cell to module to pack and even stationary racks.

Standards such as UL, IEC, UN, ISO and automotive (e.g. LV124) will also be taken into account during testing.

Besides testing and validation of batteries for R&D applications, ZF can also provide EoL testing solutions for batteries at the end of the production line. These tests serve to validate the correct manufacturing process of the battery pack. Key aspect for EoL solutions are robust systems and fast cycle times.
EoL tests include but are not limited to:

Isolation tests, HPPC tests, Leakage tests, Communication tests

The key for a successful operation of test facilities is an efficient and effective test field design considering the workflow of the test objects within the facility with the support of the available software solutions.

Our Expertise:

Performance & Endurance Testing

• Durability
• Electrical, thermal and mechanical aging
• Capacity, resistance and efficiency tests
• Swelling force measurements
  
  

Environmental Testing

• UN 38.3 transportation tests
• Vibration and shock tests
• Corrosion tests
• IP-class tests
• Vacuum chamber tests
• Dust chamber tests
  
  

Abuse & Mechanical Testing

• Crush tests
• Thermal propagation tests
• Overcharging, deep discharge, short circuit tests
• Fire resistance tests
• Drop tests

ZF Test Systems offers a proven and widely used energy-efficient solution with its ESYS.INV + ESYS.DCU/ ESYS.CMT combination.

The ESYS.INV grid-side inverter supplies several galvanically isolated DC-channels via a common DC link. In this case, the feed-in power can be designed to be much smaller than the total DC output power. For large test fields, the operator benefits from a simultaneous factor of approx. 30%. This means that the feed to the mains must be designed for only 30% of the total power of the DC output channels!

The energy is moved between the different DC output channels by means of a common DC link and the power supply only has to compensate for the missing power.

Key Benefits:

• Compact design due to lower feed-in power
• AC-in power can be dimensioned smaller than total DC-output power
• Lower investment in media supply
• Energy saving due to power distribution via DC-Link
• SiC technology leads to extremely low switching losses
• Only power losses must be covered
• Reduction of the energy fed back to the grid provider
• Lower power flow via ESYS.INV and thus lower losses
• ESYS.INV Inverter available in different power classes for maximum flexibility
• Independent galvanic isolated channels -> more than 10 galvanic isolated channels per inverter possible!