Battery Test Equipment Archives

Tag: Battery Test Equipment News

Avoiding BMS Damage During a Sudden Disconnect Event

May 27, 2022

Safety is a critical concern in undertaking battery testing, regardless of the battery format or the scale of the test. Poor safety practices or safety features in a battery management system (BMS) can result in inaccurate test data or worse, damaged batteries and risk of injury to researchers and team members. Even in the best-case scenario, the effects of unaddressed safety risks inhibit your testing progress.

While many battery chemistries will always have an inherent risk associated with their use, many of these risks can be mitigated through thorough testing and robust BMS. Protection circuits are common in most battery management systems that can disconnect a battery module/pack from a device if it senses an unsafe condition such as high temperature, cell/module voltage imbalance, or other abnormal behavior. Testing this protection circuit is important to fully qualify the BMS and battery.

Testing battery packs? Arbin’s RBT Series is engineered to test high-power batteries for complex, real-world scenarios. Learn more.

Many battery testers will not tolerate a true test of protection circuits because the sudden disconnect of a battery under test can damage the tester hardware or cause the tester to inadvertently damage the battery or BMS circuitry. Thankfully, Arbin has a solution.

Sudden Disconnect and its Potential Dangers

A sudden disconnect happens when a battery is disconnected while testing (charge or discharge) is in progress. This can happen when the protection circuit of a Battery Management System (BMS) is triggered. The BMS protection circuit disconnects the battery pack or internal modules to halt the unsafe condition that triggered it. In response, your testing equipment will immediately react to the sudden drop in voltage down to 0V.

This sudden disconnect of the battery typically happens for one of two reasons. The first is that the protection circuit has detected a true unsafe condition during the testing cycle. In the second case, the sudden disconnect is the planned result of testing the BMS protection circuit, to ensure that it works properly.

Whether intentional or not, the sudden disconnect of the battery creates several potential dangers. Your test equipment will detect the dramatic decrease in voltage and, to regain the previous voltage value, may apply the maximum possible current. In addition to the impact on the test results, the sudden increase in current could produce a spike that can damage the battery under test, the BMS, or both.

Arbin’s Protective Features

Arbin Instruments offers two features that, especially when applied together, can minimize the risks associated with the sudden disconnect of a battery mid-test. Arbin’s “damping” feature can be set in the test schedule for specific steps of the test and helps to prevent the channel voltage from reacting as strongly to the sudden disconnect.

Damping Feature Screenshot showing Damping Enabled

Damping Option in the Test Schedule

In addition, Arbin’s “voltage clamp” may be applied at an appropriate voltage limit and has a rapid response time of <1 mS. The clamp features can be applied dynamically when using Arbin’s CANBus interface. This can effectively let an external source such as a BMS control the Arbin tester in real-time.

Voltage Clamp Protection

Following a sudden disconnect situation, the Arbin system can also receive CAN message or other signal to confirm if the protection circuit did indeed disconnect the battery and stop the test.

Whether testing the function of a BMS protection circuit or running other tests, these preventative features help to ensure safety in the event of a sudden battery disconnect. They are just two of the many ways that Arbin Instruments prioritizes safety with our battery testing solutions. Our test equipment’s built-in safety features significantly reduce risk, which is especially important for a high-power testing application such as electric vehicle battery testing.

To learn more about the damping and voltage clamp features, as well as other mechanisms that reduce risk in battery testing, contact us today through our online contact form.

Arbin CAN: BMS-to-Tester Communication with Arbin’s CAN Bus Capability

March 10, 2022

Testing the Battery Management System (BMS) for a battery pack is a critical element in the battery validation process. Used to monitor the individual cells in a battery pack, the BMS can communicate essential information to an external interface, such as the battery test equipment. This BMS-to-tester communication has several important functions including verifying the BMS is functioning properly by comparing the BMS readings to the tester measurements. The Arbin CAN interface also allows the BMS to control the tester in real-time and apply dynamic “clamp” limits that can protect or further enhance the testing process. To take advantage of these features, however, the Battery Management System needs a communication protocol.

CAN bus is the most common protocol for communication between a cycler and a BMS. It provides a wide range of communication and control capabilities. Arbin’s Mits Pro employs the CAN Bus protocol, allowing CAN messages to be sent and received between the battery test equipment and the Battery Management System, and allows external control of the Arbin tester.

The Advantages of Arbin’s CAN Bus Capability

Arbin’s CAN Bus interface feature offers several important benefits for battery test operators. First, it provides you with a more flexible solution for CAN communication. Versatile enough to address a wide variety of testing applications and profiles, Arbin’s CAN Bus features can be used without third-party equipment, DLL packages, or licenses that are typically required. Through Mits Pro, Arbin’s CAN Bus functionality also allows you to define your own protocols, assign nicknames, and control tests according to your specific needs and testing standards.

Dynamic control of the Arbin cycler is another benefit of this CAN Bus feature. Unlike standard solutions, control of testing with Arbin’s CAN Bus feature is not restricted to static values for the length of the test. You can assign a CAN message to control values dynamically, with different values at various stages of a test. The CAN Bus solution also allows the BMS to fully control the Arbin testers’ charge and discharge using the CAN protocol.

The final key advantage of Arbin’s CAN Bus solution is that it facilitates communication and control between the Arbin battery tester and the Battery Management System in four distinct ways. You can customize the CAN configuration to fit virtually any requirements, allow the BMS to fully control the test equipment, monitor CAN information, and export CAN and I/V data to CSV or Excel formats for reports.

1. CAN Define: Customize Your CAN Configuration

Arbin’s CAN interface allows users to easily import their dbc file with custom CAN protocols. Once imported into Arbin’s GUI the CAN dbc is fully customizable to edit, add nicknames to CAN IDs, units can be assigned to IDs, and each can be enabled or disabled for control and logging during the test. No additional 3rd party software, licenses, or DLL packages are required for this level of convenience. A unique CAN configuration file can be assigned to each test channel on the Arbin tester.

Import and Customize CAN Configuration Protocols

The ease of import and customization to work with the CAN IDs is the foundation of other powerful abilities of Arbin’s CAN Interface. Arbin supports sufficient CAN Message IDs to allow the use of extra sets of protocols. As a result, the tester can communicate with the BMS as well as other external sources at the same time.

2. CAN Control: Fully Control the Arbin Battery Tester

Arbin’s CAN Bus capability also offers the ability to fully control your battery test equipment. This includes several key features, such as read/write integration, dynamic upper and lower “clamp” limits, and external control of the tester.

Read/write integration with the Battery Management System through CAN Bus allows for full control of the cycler’s charge and discharge. The “Write CAN Message” option can be used to send a command or multiple commands to the BMS throughout a test procedure. Through CAN messages, the BMS can tell the test equipment to charge or discharge at a particular value of current, power, etc. Including dynamic control. This communication can also be used to tell the test equipment to discontinue or slow down the charge or discharge at a certain value.

Send Commands to BMS or Third-Party Software - Software Screenshot showing Write CAN Message Feature

Use the "Write CAN Message" Option to Send Commands to the BMS or Third-Party Software

Dynamic upper and lower “clamp” limits are another important CAN Bus feature enabled through CAN messages. You can set CAN meta-variables that assign dynamic power and current limits in real-time while a test is running, rather than a single static limit that is pre-defined in the test schedule.

These dynamic limits help to increase the safety of the system during testing and validate BMS protection of the battery. For example, the BMS can limit the power during a simulation based on the dynamic limit, even when the simulation profile calls for a higher power and/or current level. The dynamic power and current limits are especially important for drive cycle simulations and similar testing applications so the simulation can run without pausing, but the BMS can limit the peak power output of the simulation.

CAN communication also allows for external control of the Arbin battery tester. An external source such as LabView can send CAN messages to control the test equipment. You can also employ the “Write CAN Message” option to send a command to third-party software throughout a test, just as you can through the Battery Management System. This is especially powerful during BMS development.

CAN Monitor: Monitor CAN Information

Another important feature of CAN is the ability to actively monitor CAN information. The Monitor and Control interface of Arbin’s Mits Pro software lets you monitor CAN details in real-time so that you can see communication and changes as they happen. Additionally, the Monitor and Control interface provides tools to send CAN messages manually.

Monitor CAN Information Through the Monitor and Control Window

On top of monitoring real-time information, the data monitoring highlights of CAN include generating reports to compare testing data. With this feature, you can conveniently cross-reference the data collected by your battery testing equipment with the data from the Battery Management System in a single results file. Having this data in one location makes it easier to compare and analyze the results.

4. CAN View Data: View and Export CAN and I/V Data

Finally, Arbin’s CAN Bus features include export options that give you even more flexibility review, store, and analyze your testing data. You can easily export both CAN and I/V data in either CSV or Excel formats with this capability. The CSV and Excel formats allow you to import your data to third-party programs for more advanced processing.

CAN Bus Data Table - Screenshot Showing Example CAN Data

Export to CSV or Excel to Process I/V and CAN Data

Using CAN Bus Communication for Power Clamp Limits

One use case for Arbin’s CAN Bus features in simulation profiles is through power clamp limits. With traditional termination limits, surpassing the limit in an EV (Electric Vehicle) drive profile, for example, means that the test is stopped, halting your testing progress. In addition, the simulation profile will have to be changed manually, to address the battery operating parameters that caused the battery to exceed those safety limits.

Although standard safety limits are still implemented along with the CAN option, CAN Bus communication offers an additional layer of flexibility. CAN protocol can assign a “power clamp” limit that is controlled dynamically over the course of the test. In this case, the BMS or modeling program will send messages that update the power output limit throughout the test.

Clamp Protections Table Showing Upper and Lower Clamp Limits via CAN Message IDs

Dynamic Upper and Lower "Clamp" Limits Using CAN Message IDs

Unlike traditional safety limits, the power clamp limit restricts the power output of the Arbin system without stopping the test. With values that are dynamic over the course of the test, this can better reflect real-life conditions and power output. Using CAN Bus communication to set power clamp limits will not only expedite the testing process, but will also allow for more complex control of the power output limits.

Arbin’s CAN Bus Capabilities and Your Customized Testing System

Arbin’s CAN Bus feature allows for communication between a BMS and an Arbin battery tester, something that is critical for many testing applications. Protecting the system and battery and actively controlling test equipment through the Battery Management System are just a few of the benefits from CAN communication.

These CAN Bus capabilities are just one of many features Arbin offers to give you the tools you need to address your specific battery testing requirements. Contact us today to learn more about using CAN with your BMS and your Arbin battery testing equipment – and more features to customize your testing setup. From drive cycle profiles and more, we can help you create a battery testing system that is ideal for your application.

The Impact of Temperature on Battery Testing

November 12, 2021

Temperature has a significant impact on battery performance. A battery releases energy through electro-chemical reactions and these reactions are encouraged by higher ambient temperatures. Different battery chemistries have different ranges of optimal operating temperatures. Depending on the application or the climate that the battery will be used in, they would be required to operate in higher or lower temperatures.

However, operating batteries at extreme temperatures also comes with risks. At higher temperatures, there is a reduction in internal resistance, which means higher electron mobility and greater charge/discharge rates. Nevertheless, studies have also shown operating a battery at elevated temperatures speeds up degradation, diminishing the cell’s life cycle.

Continuous exposure to high temperatures can also cause unwanted chemical reactions and result in gas, corrosion, or even fires and explosions. Moreover, a battery cell can enter into thermal runaway — when the cell heats up faster than heat can dissipate, causing a continuous increase in temperature. If one cell in the pack heats up, this can quickly cause the whole pack to overheat, undermining the safety of the system, machine, or surrounding people.

Conversely, lower temperatures decrease battery performance and energy capacity. Electro-chemical reactions are not as active and the internal resistance increases, damaging the battery in the long run. This is why it is extremely crucial to take temperature into account when testing batteries.

Why is temperature important in battery testing?

Battery testers and researchers need to establish how a battery would react under different temperatures to see if they are suitable for their intended application and location of use. As new battery chemistries emerge or existing ones improve, researchers must conduct testing to determine the battery’s optimal temperature range for peak performance. Moreover, this helps determine whether it is suitable for conditions they are intended to operate in. Comprehensive testing under different temperatures also helps determine which conditions can negatively impact battery performance, and allow users to better prevent dangerous situations from occurring.

How Arbin can support temperature-controlled testing

Arbin Instruments can support labs with various products when temperature-controlled testing is needed. Arbin provides three different types of battery temperature measurement options: thermocouple, RTD, and thermistor, depending on your testing needs. Thermal sensors provide reliable temperature readings so that labs can more completely assess a battery's performance. The different sensor types are appropriate for certain ranges of temperature, with varying response times and susceptibility to electrical noise. Experts at Arbin Instruments are able to help labs evaluate the most appropriate sensor for the intended application.

How Arbin’s novel battery test chamber can help

Arbin’s novel "MZTC" Multi-Chamber is a cell-isolating thermal safety chamber with 8 independent mini temperature chambers in one benchtop unit. As each mini-chamber is its own battery test chamber, it is much easier for researchers to ensure that the temperature of the chamber is stable and uniform, significantly reducing problems from uneven temperatures that that can occur with a larger chamber. It also provides users with greater temperature control and a safe testing environment. If batteries in one chamber overheat or enter into a thermal runaway event, it is less likely to cascade to other batteries inside the other mini chambers.

Moreover, Arbin offers the “MTCI” module, an interface that is compatible with many 3rd party temperature chambers when temperature and/or humidity-controlled environments are required. Using RS232 communication, users can set the temperature of a chamber during testing. Paired with Arbin’s MITS Pro software, the user-friendly interface makes it easy for researchers to not only set the temperature of the test chamber, but also synchronize a group of channels where the temperature is adjusted only after all the channels have reached the same temperature point.

Testing equipment that can best support a battery research lab will need to facilitate both safety and productivity. At Arbin, our experts can assist in planning and recommending solutions and products that best fit your requirements. Contact us now to learn more about how we can assist you with temperature-controlled testing needs

Three Benefits of Central Battery Test System Control

September 24, 2021

Why is it important to obtain large amounts of data when testing?

Data is one of the most important elements of research and testing. In various industries and fields, data gives researchers insight into the subject of study. A wealth of data also provides a foundation upon which to base findings and conclusions. Especially in an industry such as battery testing, comprehensive and extensive testing ensures safer and more efficient batteries.

Most labs would be running more than one battery tester at a time. Testing can be a long process and researchers must make good use of time in order to facilitate battery development. Moreover, conducting large volumes of testing helps researchers to identify patterns or spot abnormalities in battery performance and testing, and address the situation as soon as possible. Without multiple tests, it would be difficult to identify the circumstances under which problems or anomalies occur. It would also be harder to pinpoint situations that need attending to.

Understanding these challenges, Arbin’s expert engineers developed the Central Monitor and Control Solution (CMCS) to complement our core MITS Pro software and aid researchers in managing multiple testers. Here we outline 3 benefits to setting up a centralized control system

1. Have all your controls in one place

A centralized control system allows researchers to control multiple battery testers from one single PC. This gives researchers a better overview and easier management of active cyclers. Users can easily see what tests are currently being conducted and schedule test times. Systems like Arbin’s CMCS allow users to start, stop, and resume testing on any networked battery testers.

2. Increase lab efficiency

Monitoring each PC, tester, or system individually can be quite inefficient and time-consuming. Centralized systems also allow researchers to control the tests without having to visit each individual machine. If anything needs to be changed or updated it can be done from one PC, saving time and energy. This leaves more room for labs to increase productivity and streamline their processes.

3. Catch problems as soon as possible

Any issues that arise during battery testing can be quite dangerous. For instance, if there is a potential for thermal runaway or a short circuit that can affect the safety of the lab, it is imperative to catch it as soon as possible. Again, if lab technicians and researchers would have to check one machine at a time it could waste valuable time. It would be easier to catch it from one central monitoring system and address any issues as soon as they arise.

Managing multiple testers and cyclers can be overwhelming. Arbin’s Central Monitor and Control Solution (CMCS) allows labs running multiple testers to better manage and monitor their ecosystem of testers. The CMCS greatly simplifies the management of battery test equipment and supports labs and researchers to conduct more productive and efficient tests. Learn more about the features of Arbin’s CMCS here.

5 Reasons Your Lab Needs a Battery Rack Connection System

July 26, 2021

As the demand for battery-powered devices rises, so does the need for battery testing. In the past, the average battery current needs were around 5-10 Amps. Nowadays, the average can be up to 100-200 Amps or even more. The added power makes it more important than ever to create a safe and orderly testing environment. One way to accomplish this is by using battery racks and connection systems.

What is a battery rack connection system?

A well-planned battery rack connection system allows researchers to set up and organize their testing equipment to optimize the safety and efficiency of the lab. The system consists of shelves that can hold the batteries undergoing testing as well as cable management. Here we outline five key reasons a battery testing lab can benefit greatly from a battery rack connection system.

1. Provide a Safe Laboratory Environment

A battery rack not only provides a definitive space for batteries to be stored, but it also allows for better cable management, and together they help prevent tripping hazards and potential dangers.

With a designated space for batteries, it will be easier to keep them out of contact with conductive materials, water, seawater, strong oxidizers, and strong acids as well as other materials that could pose a safety hazard if in contact with batteries. Moreover, it also reduces the risk of physical battery damage from being dropped, falling, or being accidentally knocked over.

Batteries like Li-ion ones have the potential to start fires if misused. Proper storage ensures that the batteries do not sustain physical damage through mishandling. It also allows researchers to easily catch when batteries are damaged or puffed up by giving them a clear and organized overview of the batteries.

With better cable management, it is also easier to identify another potential fire hazard: poor electrical connections. As cables are not left on the floor or hanging between surfaces or machines, the chances of tripping in the lab and accidentally loosening connections or damaging wires could be greatly reduced. Tripping is a common cause of accidents in a lab and can be easily prevented with proper management.

2. Comply with Laboratory Safety Regulations

Safety regulations are put in place for any laboratory setup in order to better prevent avoidable accidents. Many popular cells and other batteries formats used in research are considered hazardous materials. Since batteries are also a fire hazard and may contain toxic chemicals, proper handling and lab safety is critical.

There are several standards in place to ensure that batteries and battery testing are both safe. For instance, the Lithium-Ion Batteries Hazard and Use Assessment outlines the standards set by international institutions such as the Underwriters Laboratories, the Institute of Electrical and Electronics Engineers, and the International Electrotechnical Commission. These standards are in place to ensure consumer safety and to reduce fire and failure risks. A battery rack can assist labs in conducting efficient testing with safe processes.

A well-organized lab can also demonstrate a lab’s competence and professionalism. By meeting battery and battery test standards, a lab shows its commitment to accurate and safe testing. This helps to prove reliability and credibility to a lab’s partners, customers, and investors.

3. Simplify Physical Battery Management

As previously mentioned, battery racks help researchers keep better track of batteries as well as their respective connections. Batteries can be organized by tray or by rack and can be easily labeled by channel and position. During testing, researchers can better tie physical batteries to the data collected or to specific events. When any anomalies or testing issues arise, the relevant battery can be easily found and necessary steps taken before anything happens.

4. Use Limited Laboratory Space Efficiently

Labs are full of different equipment, computers, cables, and more. Moreover, researchers would also need sufficient space to safely navigate through the lab and reach certain equipment. Battery racks keep batteries organized, and by stacking upwards, there is more space in the lab for movement or even for extra equipment. An organization system helps keep researchers' workspace clean and tidy, in turn creating a safer working environment. Racks also make it easier to store batteries in a dry, temperature-controlled space that is required for the safe storage of batteries.

5. Enable Greater Battery Testing Productivity

With organized and efficient storage, less time can be spent dealing with various issues. Battery racks reduce potential safety issues and potential hazards from damaged batteries. Batteries that show unexpected or concerning results can be identified and removed quickly. Less time can also be spent working around batteries that are stored randomly or moving batteries when more space is needed.

A lab’s working procedures will also be more efficient and streamlined with better storage. As batteries can be stored on trays, they can be easily removed and switched out once testing is complete. Organized cables will make it more efficient to run and manage the testing process. Batteries can also be easily moved to different locations as needed for different test requirements. All these together reduce the time needed to manage the testing procedures, allowing more time for productive research.

Arbin’s Battery Rack Connection System

Arbin provides battery rack solutions that suit your needs and help you to take advantage of all these benefits for your laboratory. As leading experts in battery testing technology, Arbin battery racks are designed specifically with this purpose in mind. Our racks are made of aluminum and each layer holds one battery track, each of which can hold 4 or 8 battery cells. There is a 7” space in between layers to accommodate different trays or cells. Racks also have lockable casters to keep them in place or to easily move them as needed.

Arbin also has different battery rack options to suit the needs of your lab. Racks come in different sizes: single column with 5 layers; single column with 8 layers; two columns with 16 layers; and three columns with 24 layers. No matter the size of your lab and operation, you can find a rack system that works for you. Different tray types are also available for different types of batteries, including cylindrical cell trays and pouch or flat cell trays. A plain shelf is also available to accommodate other battery holders or battery formats. Cable lengths come in 6 ft, 12 ft, 20 ft, and 30ft to provide the distance you need for convenient connections between batteries and battery test equipment.

Our experts at Arbin can help you customize your ideal battery testing solution for your lab, pairing the right equipment and support infrastructure to meet your needs. Contact us today to learn more about Arbin’s battery rack connection solutions as well as our high-precision battery test equipment.

How Nanotechnology is Facilitating Battery Development

April 15, 2021

Nanotechnology is science at the nanoscale, working at the atomic or molecular level of matter. A nanometer is one billionth of a meter -- invisible to the eye. Nanotechnology is being used to innovate in many different fields including medicine, the environment, technology, and energy storage. The concept of nanoscience first started in 1959 when physicist Richard Feynman spoke about manipulating and controlling individual atoms and molecules. The field as we now know it began in 1981, when the scanning tunneling microscope was developed, which allowed scientists to see individual atoms and begin research at the nanoscale. In the battery industry, many companies are working to incorporate nanotechnology into batteries and battery production processes in hopes of improving material mining and battery performance and capacity.

How is nanotechnology improving material mining?

Lithium is currently the most coveted material needed for batteries. With the continuous growth of portable technology and EVs, and an increasing need for energy storage, analysts predict that the demand for lithium will increase tenfold by 2029. 70% of lithium is mined via brine extraction, which involves pumping salt-rich waters into a series of evaporation ponds. The water evaporates and pure lithium is eventually extracted from the ponds. However, this process is not only water-intensive, affecting the water supply to nearby residents and farmers, but also only extracts 30 to 50% of the available lithium.

One company is working to make use of nanotechnology to improve the efficiency of this process. EnergyX makes use of a nanotechnology called Metal Organic Framework (MOF) to separate lithium from the other materials in the water. An MOF is a porous material, consisting of metal ions and organic ligands that form a cage-like structure. They can act like a sieve to segregate materials, which is how EnergyX is making use of it. The small pores of the MOF allow lithium to pass through, but stop other ions like magnesium or calcium, allowing for a more efficient way to extract lithium. The company designed their technology to incorporate into the current brine ponds system, maximizing the mining process. Creating more efficient, sustainable, and environmentally-friendly mining processes can be a big help in meeting the demand for lithium and other battery materials

How is nanotechnology improving batteries?

There are currently numerous projects around using nanotechnology to create better batteries. These range from increasing the surface area of electrodes in order to increase capacity to improving the safety and stability of the battery.

The advanced materials company TruSpin Nanomaterial Innovation makes use of silicon nanofibers to increase the energy capacity of lithium-ion batteries. Silicon has long been a favored choice as a battery anode because of its high ion-carrying capacity. However, due to its tendency to expand and shatter throughout charge/discharge cycles, manufacturers are facing difficulties in incorporating it into a battery. Nanotechnology can help to address this issue. By using nanofibers, TruSpin is able to work around these expansion issues, and make the manufacturing process highly scalable and cost-efficient.

Amprius is another company leveraging nanotechnology to make silicon more usable for batteries. They designed egg-like capsules to protect the silicon from reacting negatively with the electrolyte, which causes the anode to develop a non-conductive solid-electrolyte interphase layer and reduces capacity. The structure also gives room for the silicon to expand and contract safely. In their design, a silicon nanoparticle is surrounded by a highly conductive carbon shell that lithium ions could pass through. With this configuration, their team found that the anode still retained 74% of its capacity after 1000 charge/discharge cycles.

Pure lithium metal is also a highly favored battery material. However, since it is highly reactive, dendrites tend to form on the surface of the anode, creating branch-like structures that can pierce and damage the battery. To counteract this, scientists at Rice University made use of carbon nanotube film to coat the lithium metal foil. The coating discourages li-ions from latching onto the lithium metal anode and prevents dendrite growth.

Despite its miniscule size, nanotechnology has the potential to make big waves in battery development, research, and manufacturing. Good, high quality battery test equipment allows researchers to notice patterns and gaps in a battery’s performance, and discover areas which nanotechnology could potentially help to fill.

30th Anniversary- Celebrating the Past and Looking Towards the Future

January 6, 2021

Link to Podcast

This year will mark a big milestone for Arbin Instruments, as the leader in the battery and energy storage testing space will turn 30.

“Arbin’s customers come back because they know their sales engineer and the support team and the product team, and everyone is going to give them their 100% to make sure they have the reliable testing equipment that they need and the most innovative product they need to continue with their research,” Price said.

Learn more how Arbin can help you in your battery testing needs.

5 Features of Arbin’s Regenerative Battery Testing Series

June 17, 2020

A battery intended for a smartwatch should be tested with a slow and steady discharge profile that mimics the watch’s energy use in actuality. Conversely, a battery intended for larger applications such as electric vehicles, should be tested with dynamic test profiles that simulate how a car is used and driven. Battery test equipment should be able to test cells in a way that can accurately examine the cell with regards to its intended application. For instance, Arbin’s Regenerative Battery Testing (RBT) series is designed specifically for high-power batteries used in applications such as electric vehicles, military and stationary grid storage.

All of Arbin’s equipment is designed around the principles of flexibility, safety, and dependability. Learn more about the key features of our RBT series below.

Made for high-power applications

The RBT series is designed to test large battery packs. Providing wide voltage and current ranges and a high power range of up to 1MW.

The simulation control feature of the RBT allows the system to charge or discharge according to a dynamic test profile. For electric vehicles, this would mean importing a drive profile that mimics how energy and power demand changes during a drive. In an application such as grid storage, the test profile could mimic how the grid would collect and release energy throughout a certain period of time. The ability to conduct tests in this way is important to see how the switching between charging and discharging or the fluctuations in power requirements would affect the battery pack. Making use of true bipolar circuitry, there is no switching time between charging and discharging, meaning that more accurate simulations can be achieved. Each system is also built to run continuously at maximum power so there is no fear of overpowering the system if tests need to be run at high power for long periods of time.

Easy to program and collect data

Testing systems come with a PC equipped with MITS Pro, Arbin’s software package. The software is completely user-friendly and programming dynamic test profiles is simple. A text profile of time-vs-power or time-vs-current data in .xlsx, .csv, or .txt formats can be directly uploaded to the system. The system can safely handle thousands of data points to run your desired simulation.

Test profiles are completely customizable and easily programmed using dropdown menus. Parameters for different experiment controls such as current, voltage, power, load, and many others can be input directly into the system. All testing channels are completely independent but can also be combined to operate in parallel.

Data can be logged based on changes in Time, Current, or Voltage; data analysis and plotting tools are based in accessible programs such as Data Watcher and Microsoft Excel.

The goal of Arbin’s software is to simplify and streamline the testing process so users can get the most accurate and precise results.

The system has built-in safety features

Accidents or mishaps in battery testing can be dangerous. Circuit overloads, overheating, overcharging or over-discharging are problems that can occur during testing. MITS Pro also allows users to program safety limits for current, voltage, total power and more. Once a channel reaches the set limit, the system enters a rest state for a period of time, or halts the test altogether.

The system is also equipped with an emergency stop button and multiple levels of fusing to protect it from unintentional misuse. The equipment has onboard microcontrollers that will stop tests if there is a failure that poses a risk. These features are crucial in halting any problems as they arise, ensuring a safe testing environment.

An economical and efficient solution

One special feature of the RBT system is its use of regenerative circuitry to discharge power back to the grid. The system is able to send power back to the grid with >95% efficiency, making it a more economical solution by decreasing the net energy consumption of the system. This also helps facilitate the overall cooling process by reducing heat dissipation.

The discharge power is also cleaner than before with the total harmonic distortion as low as 3%.

Customizable to meet your needs

There are multiple auxiliary options that can be added to the RBT system to fit your testing needs. Extra options would allow users to better monitor individual cells within a pack. Temperature measurement channels and temperature chamber interfaces are available, which would give users more flexibility in measuring and controlling temperature during testing. CAN-bus communication is an option to test battery packs with integrated Battery Management Systems, which can help communicate valuable messages to the MITS Pro software. Digital or analog input/output modules can further help control testing procedures.

A comprehensive system that provides easy to use features greatly facilitates the testing process. High-power dynamic applications especially require strong and power-efficient equipment to conduct meticulous and rigorous testing and ensure safe procedures.

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.