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Safe Testing for EV Batteries

September 12, 2019

Why researching Electric Vehicles batteries has never been safer

Advancement in battery testing equipment has made the process of battery testing safer. With more [precise and accurate testing equipment], the smallest changes in a battery can be detected before it becomes a critical issue. Improved equipment also allows for a more stable and controlled testing environment, making the [research and development process] much more efficient.

The safety concerns with EV batteries

While electric vehicles (EV) have been on the road for a while, questions regarding the battery’s stability and safety still come up. A few of the major, key issues with EV batteries are flammability, gases, and trauma to the battery cell.

As with any device that uses lithium-ion batteries, flammability is a huge concern with EV batteries. There have been cases where EVs have experienced thermal runaway events with catastrophic failures. Battery fires require special equipment to extinguish, and if one’s not careful, the batteries can reignite even after the fire is put out.

Common electrolytes found in batteries are mixtures of carbonates and a dissolved salt. In the event of a thermal runaway, decomposing electrolytes lead to a formation of gases within the cell, increasing pressure within the battery, leading to the release of toxic gas.

Trauma and impact to the battery pack can also greatly affect its capabilities and compromise its stability and safety. EVs have been reported to spontaneously combust days after being in an accident, showing how the risks are real if batteries are not properly monitored. This is equally true during testing; even in a lab environment.

How Arbin’s equipment is designed to test EV batteries

Arbin’s equipment allows batteries to be tested using dynamic cycling. Traditional batteries are mainly tested with constant current charge/discharge profiles. On the other hand, EV batteries need to charge and discharge dynamically, based on the car’s action.

Arbin’s systems make putting the battery through a dynamic cycle easy. Using [Arbin’s software], standardized test profiles, such as USACB's FUDS profile can be easily uploaded into the testing system, allowing batteries to be safely and efficiently tested according to regional, national, and international standards just by uploading a text file of time-vs-power or time-vs-current data to simulate the drive cycle. [LEARN MORE] High quality and precise testing equipment detect the slightest change in the battery, allowing researchers to detect any issues early on in the testing process and know better what materials and situations affect battery health and life. Researchers can catch these changes and make appropriate adjustments to the battery before it becomes a critical issue. It also allows manufacturers to create comprehensive safety guidelines for use of the battery. Battery test equipment from other manufacturers has been shown to significantly average the output of a dynamic drive profile and fails to accurately reproduce the real-world requirements.

It is also possible to have the EV battery pack’s battery management system (BMS) fully control the Arbin tester charge/discharge via [CANBus protocol]. This software is not limited to cutoff limits or safety conditions like other brands of test equipment, but can also be used as dynamic control values.

Temperature stability is also key in testing EV batteries. As mentioned before, overheating batteries is a serious safety hazard. Creating a stable thermal environment in which batteries can be tested is crucial to safe testing. It is also imperative to contain any problems in the event of a thermal runaway or cascade failure so as not to affect other batteries within the test chamber.

Arbin Battery Test Chamber

[Arbin’s multi-chamber equipment] isolates each battery cell or pairs of cells during testing, creating a safer and contained test environment that maintains temperature stability. Each chamber is thermally isolated and can have its own unique temperature set point so as to keep batteries from affecting each other during testing. This is a safer and more accurate testing method to see how temperature affects batteries.

Conclusion

Batteries are a critical component of the increasing global need for energy storage, including electric vehicles. Thus, testing processes must be able to meet the demands of the research needed for the technology to develop. Better testing equipment not only accelerates the testing process, allowing manufacturers to innovate and improve at a greater speed, but also makes testing and the creation of batteries safer overall.

Batteries in Space

September 12, 2019

What makes batteries used in space different?

Batteries used in space undergo extensive research, testing, and development to an even greater degree than batteries used on earth. In such high risk situations, the failure of batteries is extremely dangerous. The process of changing batteries can also be a taxing mission. It took astronauts 6.5-hours to change a set of batteries of the International Space Station. Due to the extreme conditions of space, batteries need to be custom made to fit each mission, environment, and temperature, as well as have the ability to perform its function well in these circumstances, so as not to jeopardize the safety of people involved.

What kind of batteries are used in space?

As on earth, rechargeable lithium-ion batteries are currently the favored choice in space. Using the International Space Station as an example, the batteries used to power the station are recharged with solar energy from the sun and the energy stored is used when it is in orbital darkness -- when the station is in the earth’s shadow and not in direct sunlight.

In 2017, NASA began the process of replacing the nickel-hydrogen batteries on the Space Station with lithium-ion ones. Nickel-hydrogen batteries were initially used in space technology because of their long battery life and ability to withstand many charge and discharge cycles without significant degradation. However, the extra process of battery conditioning was necessary in order to combat the cells’ “battery memory” which sees a battery lose a portion of its capacity if not fully charged and discharged every cycle.

Lithium-ion batteries were a welcomed upgrade to the 20-year old station. Being more light-weight and energy-efficient, just one lithium-ion battery was needed to replace two nickel-hydrogen ones, a vast upgrade in energy and volume densities. The new batteries are also not susceptible to battery memory, negating the need for conditioning. Nonetheless, each type of battery still has its own drawbacks. Lithium-ion cells are more sensitive to overcharging, overheating, and cases of thermal runaway. Thus, battery testing is crucial and any battery used in space must be subjected to rigorous testing before being certified safe for use in space.

The difference between batteries used in space and common batteries

The lithium-ion batteries currently on the Space Station are extremely heavy-duty and made to last much longer than the average battery used in everyday life. The average rechargeable lithium-ion battery found in common appliances such as cell phones lasts about three to five years, or 500-1000 complete charge cycles; the batteries used in electric vehicles are made to last eight to ten years and a few thousand charge cycles; batteries on the Space Station have been designed to last for ten years and 60,000 lifecycles. The standards for batteries is space in much higher. Strict and comprehensive testing is needed to meet these requirements.

Testing batteries made for space

Since batteries release energy through chemical reactions, the environment in which they operate affects their performance. Because of the extreme conditions of space, batteries need to undergo intense testing under a number of different conditions in order to be certified for use.

For instance, batteries need to be tested under vacuum conditions. Research has found that overcharging the battery did not lead to thermal runaway, whereas an external short circuit test did. These results are the exact opposite of the same tests being performed in ambient pressure environments. Batteries are also often put under abuse tests to understand the worst case scenarios as well as the steps necessary to avoid these situations and properly manage the battery.

Moreover, based on the mission, batteries need to function in circumstances not encountered on earth. For example, some missions require batteries to work in extreme low temperatures of -20 to -100°C. Temperature greatly affects the rate of charge and discharge, thus it has to be made certain that the batteries can function at these temperatures.

As with any battery, overheating and overcharging are huge safety concerns. Proper battery management systems and [battery testing equipment] must be used in order to ensure the safety and stability of a battery, most especially in space where the stakes are high. In these circumstances, precise and reliable test equipment is critical.

Space technology on earth

While uses of such a heavy duty battery as used in space is rarely necessary on earth, the innovations made in space technology have a trickle down effect, eventually capable of being used in everyday life without us even realizing its origin. Cameras now commonly found in mobile phones, DSLR cameras, and other portable devices can be traced back to NASA scientist Eric Fossum, whose work in miniaturizing cameras for interplanetary missions made is possible for cell phones to have good quality cameras.

Thus, any innovation from research on space technology and batteries used could one day help and benefit the masses, improving the batteries and appliances we use in everyday life.

Conclusion

Continuously improving and innovating at the battery testing level is also crucial to the research and development of batteries. When testing equipment can keep up with materials research and dynamic charge/discharge profiles to mimic how appliances and technologies would use batteries, better predictions and assessments can be made. If the heavy duty [battery technology of space] is one day incorporated into everyday technology, commercial battery testing equipment should be able to meet this demand.

Where Are The Flying Cars

July 24, 2019

Introduction
No longer things of science fiction, flying cars are slowly becoming possible as many companies are working to release the first commercial and affordable flying car. These vehicles aim to be alternatives to conventional cars, and through their adoption alleviate road traffic, make short-distance travel faster, and provide a more environmentally friendly option for travel.

There are two design streams when it comes to flying cars currently under development. The first, eVTOLs (Electrical Vertical Take-Off & Landing), otherwise known as passenger drones, are close in concept to small drones seen on the market now. The second are hybrids, vehicles that have both wheels and wings and can operate on the road and in the air.

Plenty of companies have already developed prototypes. If the technology is already available, what is really stopping us from having flying cars now?

Why flying cars?
As the world taps into its finite fuel reserves, companies and researchers are racing to find efficient and affordable fuel and transportation alternatives. Electric vehicles (EVs) reduce the need for combustible fuel. They are also better for the environment as they reduce carbon emissions and noise pollution on the road. As a replacement for short-to-medium distance travelling, electrical flying cars would reduce the emissions from, and fuel used for trains, planes, and road vehicles.

Compared to electric cars, conventional cars are inefficient in their energy use. Currently, EVs convert around 60% of their energy to propulsion, while only 20% of every litre of fuel burned is used for forward motion in a conventional car. The rest is lost to heat and noise. In the same way, flying cars would allow for better use of energy when compared to fuel-based vehicles.

Commercial air travel has proven to be significantly safer than road travel. Thus, the standards set for the safety of flying vehicles would be higher than that of conventional cars, prompting developers to ensure they would be a safe option for daily use. Moreover, the advancement of technology has allowed for autonomous vehicles, aiming to eliminate human error. This technology is also being worked into flying cars.

Flying cars also allow for more mobility in a shorter amount of time. It would reduce the time spent commuting or stuck in traffic, giving people more time for other activities, like spending time with family and friends. In an urban city where life is busy and fast paced, the extra time would be warmly welcomed.

What still needs to be improved?
Technologically and economically, flying vehicles have not reached a level of efficiency which would allow it to be an effective mainstream option of travel. Ultimately, in order for electrical flying vehicles (eVTOL’s) to become reliable, safe, efficient, and affordable, battery technology still has a long way to go. Compared with jet fuel of the same weight, currently available batteries are just not as efficient for flying. According to one study, a single passenger eVTOL is still less energy efficient than electric road vehicles. The batteries of today are still unable to carry the amount of energy needed for flying vehicles to be considered energy efficient. Moreover, since these batteries would be extremely heavy-duty, the charge rate would be too slow to support flying vehicles as a high-frequency option for travel.

Besides capacity, the heat generated from the release of power is a huge concern. Batteries in eVTOLs and flying vehicles need to discharge much quicker than road vehicles, requiring special cooling systems, adding to the weight of vehicles. The extra heat would also shorten battery life and possibly make them more prone to catching fire. There are current problems with EVs catching fire while charging or after being involved in accidents. The instability of the safety of batteries must be addressed before flying vehicles can be considered a safe and viable option of public transportation.

What are the next steps?
Developing the right battery is still the key to creating a flying vehicle that can be clean, green, and efficient. Battery testing must also catch up with the needs of battery and vehicle developers to better understand what can be done to make them better. [Battery testing equipment] should be able to detect the smallest changes in the battery early in the testing phase so researches can quickly pick out factors that affect battery health. Equipment like Arbin’s cuts through the measurement noise present in lower quality equipment, allowing researchers to see minute changes and trends. Thus, more effectively assessing and predicting the efficiency and health of the battery.

Temperature control equipment like [Arbin’s MZTC Multi-Chamber], also helps ensure superior measurement precision and safety during testing. Accelerating the [testing and development process] by reducing the chances of one battery cell affecting the other and causing issues like cascade failures. With flying car batteries, where heat and temperature control is crucial, having the right battery testing equipment is critical.

While solid concepts for flying cars are present and the projected benefits of using them are good, technology has yet to catch up to our imagination. However, once battery technology is able to meet the safety standards and efficiency needs of a flying vehicle, commercial, mainstream flying cars will become transportation of the present.

Drones are flying further thanks to battery test equipment

July 10, 2019

Drone technology has come a long way since its first introduction into non-military consumer use in 2010, becoming lighter, faster, and more compact over the years. Improvement in battery technology and battery testing equipment has greatly contributed to the advancement in drones, allowing smaller batteries with higher volumetric and energy densities to carry drones further than before.

Batteries as a limitation
Capacity, safety, and the lifespan of batteries are all factors that limit the creation of faster and more efficient drones. In the current state of battery technology, high capacity batteries are big and weighty, restricting the potential of portable and mobile devices as heavier loads would need a larger amount of energy to be carried. Most commercial drones fly for an average of 10 minutes before needing to be charged for an hour or two. The longest-lasting drones run for around 30 minutes, but the high price of heavy duty batteries increase the upfront cost of the gadget, making these drones also quite pricey.

Latest in battery technology
Researchers and battery chemists are working to improve on the various limitations of batteries and contribute to the progress of portable devices. Some of the solutions currently being worked on aim to find alternative materials that could replace various components of the battery to store more energy and release power more effectively, as well as increase the efficiency and thermal stability of batteries. This could be finding replacements for anodes, cathodes, or the liquid electrolyte found inside batteries. Better, more efficient materials would mean batteries with higher capacities, longer life-spans, and less flammable units, thus making portable electronics, gadgets, and electric vehicles much safer and more reliable. However, research and development within this field is slow and arduous and most researchers so far have found that to improve one element is to compromise on another. There must be a delicate balance between improving technology and ensuring the safety and efficiency of new batteries and products.

The benefits of battery testing and improved battery testing equipment
This is where improved battery testing and battery testing equipment can help maintain the balance between safety and progress. Advancement in testing equipment allows for more efficient and precise testing, measuring the smallest changes in a battery under real-world test conditions. Since many factors affect battery health, such as temperature, charging speed, depth of discharge, load cycles, etc., it is crucial to test these factors to ensure the safety and longevity of batteries and know better how to extend and improve the lifespan of products.

Typically, testing a battery would involve charge cycling for a significant portion of the battery’s expected lifespan. For instance, if a battery is meant to last for around 2 years, testing would last several months and the health of the battery would be projected from its test results. However, now that batteries need to last for more than 10 years, to test them for 2-3 years makes the development cycle too slow. Thus, battery testing equipment must be able to detect the smallest changes in the battery early in the testing phase so researchers can quickly compare batteries and materials. Drone batteries need to be able to release a large amount of power in a short period of time to take off and land as well as maintain a stable power flow while cruising. Better battery testing equipment allows the minute changes within the battery to be detected during these energy releases so researchers can better know what affects the battery and what needs to be changed to make them more energy efficient. Arbin’s battery test equipment offers the best measurement precision by a significant margin, allowing researchers to see the smallest changes and trends within the battery that go undetected among measurement noise with lower quality test equipment. This accelerates the testing and development process, allowing battery-powered devices like drones to improve more rapidly.

Arbin Battery Test Chamber

Safety is also a critical concern during battery testing. It is crucial to measure and control temperature during testing to prevent a failure or thermal runaway event. A typical temperature chamber provides a single large space to test a number of batteries at the same temperature in one go. However, if one battery cell fails, it could cause a cascade failure or ruin other tests in the same chamber. Thus, Arbin has created the “MZTC” Multi-Chamber that isolates cells or pairs of cells into individual mini-chambers to provide greater temperature uniformity and safely isolate cells from one another in case of failure. This speeds up the testing process by stabilizing tests and reducing risks.

How battery testing can help drones fly further
For drones, other portable devices, as well as electric vehicles to improve and become more accessible, battery technology still has a long way to go. However, with better battery testing equipment the research and development process can be reduced with greater resolution, superior precision, and a more consistent test environment, allowing technology to soar to new heights.

Use Autolab EIS with Arbin LBT Cell & MSTAT testers

May 27, 2019

Arbin is proud to announce a new partnership with Metrohm Autolab to integrate the PGSTAT204 EIS with your Arbin test channels. Use the PGSTAT204's EIS multiplexed (shared) across up to 32 channels on your Arbin LBT Cell or MSTAT model to maximize the duty cycle of both instruments.

The Autolab PGSTAT204 joins Gamry's 1010E, 5000P/E, and 3000 models as compatible with Arbin's multi-channel testers. Dramatically increase throughput of your battery materials research with the Arbin LBT Cell or MSTAT tester and a multiplexed EIS. Perform charge/discharge cycling, PITT, GITT, Cyclic Voltammetry, DC IR, measure Coulombic Efficiency, Capacity Fade, and more with the Arbin channels and measure EIS as often as you'd like without changing connections.

Researchers Use Arbin Battery Test Equipment to Develop AI Predictions of Battery Life

April 9, 2019

A recent [Nature] publication from researchers at Stanford University, MIT, and Toyota describes how machine learning models can be used to predict the useful life of advanced lithium-ion and any future "next-generation" battery chemistry. [News Article from Stanford] The research team used Arbin battery test equipment over the past two years for the on-going study.

About the Battery Research Project

Batteries were tested to end-of-life and then machine learning was used to analyze the Arbin data and develop algorithms to predict battery life based on early cycles. Charge-discharge cycling to end-of-life can take months or years for advanced chemistry batteries comprising many thousands of cycles. It is a slow and costly phase of the battery research and development process. Expediting this process by identifying key metrics and indicators in the data during early cycles (<100) is critical to reduce the time required for battery development. Beyond material development and cell-grading, these evaluation testing techniques can also be used to evaluate fast-charge protocols, which is the next phase of the research project.

The joint team has published data that is available publicly [https://data.matr.io/1/].
Arbin [LBT test equipment] and [cell holders] were used along with temperature chambers.

Request a Quote or Contact us to learn more: sales@arbin.com | +1 979 690 2751 | www.arbin.com

Why Arbin is Most Suitable for This Level of Battery Research

Previous research has been done using coulombic efficiency as the primary metric to predict battery end-of-life [Source]. Arbin was involved in a 3-year [ARPA-E project] from 2012 through 2015 with Ford Motors and Sandia National Lab to develop a new generation of high-precision battery test systems that are capable of performing meaningful coulombic efficiency calculations on high-current cells. This technology has been implemented across [Arbin’s cyclers] and is available to researchers worldwide.

The new findings from the team at Stanford, MIT, and Toyota is another breakthrough that has utilized Arbin’s 24-bit resolution and superior measurement precision. Arbin has also recently developed a new [cell-isolating thermal safety chamber], "MZTC," that has 8 independently controlled mini-chambers in 1. It allows greater temperature uniformity by isolating individual or small sets of cells that can reduce the error calculation and further improve the machine learning algorithms to evaluate battery life. It also provides a safer environment when testing cells at high c-rates.

Arbin Battery Test Chamber
Arbin Battery Test Chamber

Arbin is committed to providing the best test equipment as a tool for researchers because we understand the import role energy storage plays in our everyday life and future. Battery test equipment is available for [materials research applications], up to [commercial cell testing at high c-rates]. [Arbin’s cell-isolating thermal safety chamber] also provides a greater temperature stability and uniformity than a traditional large chamber can provide.

Request a Quote or Contact us to learn more: sales@arbin.com | +1 979 690 2751 | www.arbin.com

[Learn How to Evaluate Battery Test Equipment]

Expansion in 2019

December 20, 2018

Arbin is expanding in 2019 to increase production line testing capability. Dozens of new input power lines have already been installed in our 65,000 sqft. headquarters in Texas.

There has been extreme demand for our high-power battery testing systems and we are working hard to keep up.

NASA turns 60

November 9, 2018

USA Today - NASA special edition

Join Arbin in celebrating NASA's 60 years of achievements!

USA Today released a Special Edition publication looking back at NASA's past 60 years, and looking forward at what is on the horizon.
View this special edition publication for free and check out Arbin's ad on page 33.

Energy storage is a critical requirement to achieve our goals in space travel, exploration, and technology.

When battery performance and safety have the highest demands, researchers trust Arbin test equipment to generate data they can rely on.

Arbin battery test equipment is capable of simulating elliptical solar charge orbits, advanced materials research with EIS, basic cycling, and most everything in between.

Evaluating Battery Test Equipment – Introduction

October 19, 2018

Batteries are a critical component of many products, and energy storage plays a very active role in our lives even outside of the research/industry setting. Therefore, selecting the right battery test equipment is an important decision for companies and the individual researchers who are responsible for producing results, whether they are starting small, or at massive scale.

The expert engineers at Arbin have been advancing the benchmark of “state-of-the-art” battery test equipment for over 27 years. We are defined by innovation, from being the first to apply multiple current ranges on a single test channel to more recently being the only company to offer true high-precision testing for high current applications, and supporting “Turbo Mode” with smart battery modules. We continue to learn from our industry partners and work with them on key technology breakthroughs.

The following report shares some of this knowledge using plain terminology and illustrations. Here are five key topics to consider when choosing battery test equipment:

Click to request access to the full report: "How to Evaluate Battery Test Equipment."

1. Hardware - Specifications & Quality of Materials [Continue Report Preview]

2. Software - Usability and Features

3. Data - Logging, Management, and Analysis

4. Options - Auxiliary Features and Accessories

5. Support - Product Safety and Support

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Evaluating Battery Test Equipment – Part 6/12 – Software Usability & Features

October 18, 2018

Easy to use drop-down lists to build test profiles

All battery test equipment requires software to operate the instrument. The software interface can be one of the main differentiating points besides hardware performance. It is important to confirm the software communicates using a modern high-speed standard such as TCP/IP (Ethernet) protocol and whether high-performance microcontrollers are used internally. This helps future-proof the system as well as meet the bandwidth necessary for fast data logging.

A software user interface should use familiar commands and follow a logical process to create tests, but also needs the flexibility to control advanced test protocols. The best software will not restrict the researcher to pre-defined test parameters, but will give full authority over the equipment’s voltage and current control. The following questions will help identify a complete feature-set:

Simple method to implement drive cycle or other simulation

Are capacity and energy calculations made at the micro-controller level or post-processed data?
Is there a limit on the number of steps per test?
How can an EV drive profile be performed?
Do tests utilize branching and looping conditions?
Can tests utilize multiple condition like this for each step and combine logical functions?
Can tests use mathematical functions?
Can the software use meta-variables instead of numeric values only, such as stopping a test based on
Easily group any number of channels in parallel

“80% discharge capacity” instead of only a numeric value?
How many of these meta-variables are offered?
Can tests be controlled using C-rate values instead of amperage if the cells under test vary in capacity?
Can channels be connected in parallel to increase the current capability? If yes, then how many?

Arbin allows all these methods and more to apply dynamic and complete control of voltage, current, power, & load, and offers user-defined variables in addition to the 90+ standard meta-variables.

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