Maximum Safety and High Performance in Battery Pack Testing

The global mega trend toward electrifying tools, machines and vehicles creates a huge demand for the development of new products such as drives, semiconductors, energy storage, cabling and infrastructure. Rechargeable lithium based batteries, power packs or energy storage modules need to be approved and certified according to IEC and UL standards and subjected to functional testing together with the product or vehicle as a whole.

HBM power meters and data acquisition products are the first choice for facing this challenge and getting reliable measurement results in a safe way, when testing big battery packs or complete drivetrains in lab or mobile use. 

Apart from high-quality and safe inputs for voltage, current and temperature measurement, the relevant HBM products such as the QuantumX and the GEN DAQ eDrive testing solution are freely scalable and allow for solving even challenging projects with additional physical parameters like strain (optical, electrical), weight, digital bus communication via CAN/xCP with a Battery Management System (BMS) or Charging Station.


Benefits of HBM Data Acquisition Systems

Reliable and Safe

  • Highly accurate (immune to noise)
  • Fully isolated (high CMRR)
  • Maximum safety (touch-, shock- and fire-proof connectors)
  • VDE proven safety

Easy to Use

  • Distributable and short sensor line
  • Ethernet connection to any PC
  • Easy to use software
  • Visual Studio and LabVIEW™ driver
  • Real-time integration via EtherCAT

Modular and Extensible

  • Single module or chassis system
  • Freely scalable system
  • All necessary inputs and outputs
  • Sample rates from S/s for static tests to several MS/s for dynamic tests

Example Test Cases

  • Power and energy efficiency analysis
  • DC and AC impedance testing
  • Long-term measurement for durability or life time analysis (cycle simulation, power cycling, charge and discharge rate, self-discharge, fast charge)
  • Ambient influences (temperature)
  • Charging station test
  • Overall system test in the complete drivetrain including electric drive and simulated loads (testing of functionality, power, efficiency, range, reverse load feedback—regenerative braking)
  • Fault testing (overload, short-circuit, overheat, mechanical load, defect)
  • Battery management system test (overload protection)
  • Dynamic load investigation (current ripple)
  • Electric impedance spectroscopy

Standard solution: QuantumX

From a few to hundreds of channels and up to 100 kS/s per channel: The QuantumX data acquisition solution is freely scalable and can work PC-tethered in the lab, integrated in real-time or mobile. It can analyze and record data, and control loads via digital or current output. All relevant signals can be acquired in parallel and time synchronously, in a safe way:

  • Voltage range from 5 to 1500 V (transient proof)
  • Current from mA to hundreds of A via current transducers
  • Temperatures with thermocouple type K, J, T, E, N and 1000 V isolation
  • Strain, force or load using electrical strain gauges or optical strain gauges
  • CAN bus signals

The powerful catman software provides a scripting engine for additional analysis, for example, of power or efficiency for analysis of certain load cases. Recorded raw data can be exported to all common data formats: MAL, EXCEL, ASCII, MDF, …

Testing at high sample rates: Genesis High Speed

Modular Genesis High Speed mainframes with plug-in boards offer 1 kV isolated inputs with sample rates up to 2 MS/s for high speed investigations on ripple currents and AC impedance tests on any number of channels. All results can be logged and transferred straight into MATLAB.

  • Voltage range from mV to 1 kV
  • Current from mA to hundreds of A via current transducers or clamps
  • Temperatures with thermocouple type K, J, T, E, N and 1000 V isolation
  • Strain, force or load by electrical strain gauges
  • CAN bus signals

Perception software is perfectly tailored to the requirements of highly dynamic signals and associated power calculations.

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