Rechargeable Battery Evaluation

Sustainable Manufacturing Processes of Rechargeable Batteries

Material Evaluation

Lithium-ion batteries used in next-generation vehicles, especially electric vehicles, require various evaluation tests to ensure their safety. Typical insulation evaluation tests include withstand voltage tests and insulation resistance tests. These tests are essential to ensure battery safety.

Kikusui Electronics is a leading manufacturer of safety-related testing equipment, offering a diverse product lineup.

Impedance measurement of the electrode foil is performed on the lithium-ion batteries before electrolyte injection.
Kikusui’s BIM1000 series battery impedance meter measures low resistance using the 1kHz AC 4-terminal method. It is also capable of measuring voltages up to 1000V.

Safe and accurate! This device measures insulation between electrodes and between electrodes and the exterior.

Withstand Voltage Tester
TOS5301

Specifications

Highly stable output thanks to PWM amplifier
AC withstand voltage test of 5 kV/100 mA (500 VA)
DC withstand voltage tester with 6 kV and a maximum output of 50 W
High accuracy measurements of ±1.5% of reading (at 500V or more for voltmeter and 1mA or more for ammeter)
Rise/fall time control
Key lock & actuator cover
Equipped with USB interface

Insulation Resistance Tester
TOS7200

Specifications

Output voltage setting range: -25 to -1000V
Resistance measurement range: 0.01MΩ to 5000MΩ
Equipped with a discharge function
Equipped with a window comparator
Hold function (holds the measured resistance value during the PASS period at the end of the test)
Equipped with a timer function
SIGNAL I/O, Remote control terminals
RS-232C interface included as standard

Easier, more accurate measurement of electrode foil resistance

Impedance Meter
BIM1000 Series

Specifications

Measured voltage: max. 1000V (BIM1100), max. 300V (BIM1030)
Voltage measurement accuracy: ±(0.01% of reading; 3 digit)
Resistance measurement accuracy: ±(0.5% of reading; 5 digit)
Resistance range: 3mΩ / 30mΩ / 300mΩ / 3Ω
High resolution: voltage 10μV (6V range), resistance 0.1μΩ (3mΩ range)
Measured frequency: 1kHz ±0.2Hz
Sampling rate (voltage & resistance measurements): 20 ms (at FAST)
SIGNAL I/O, RS232C, and USB included as standard

Partial discharge function detects potential insulation defects!

Electrical Safety Standard Multi-Analyzer
TOS9301PD

Specifications

The maximum applied voltage for AC withstand voltage test: 5kV/100mA (500VA)
The maximum applied voltage for DC withstand voltage test: 5kV/20mA, 7.2kV/13.9mA (100W)
Insulation resistance test measurement range: 0.001MΩ to 100.0GΩ (-25V to -1000V DC/+50V to +7200V DC)
Models with partial discharge function allow for insulation diagnosis.
Dielectric breakdown detection sensitivity can be set.
LAN/USB/RS232C included as standard

Partial discharge tests can identify insulation defects in separators and other components caused by pinholes, scratches, and voids. Since the TOS9301PD is equipped with a partial discharge function, it can measure the increase in charge before dielectric breakdown occurs. Therefore, this device is capable of detecting potential insulation defects that cannot be revealed through withstand voltage tests.

Single Cell Evaluation

With the increasing popularity of electric vehicles, the importance of safety is increasing, which is driving rapid advancements in the development of solid-state batteries. Solid-state batteries resemble lithium-ion batteries in structure but utilize a solid electrolyte instead of a liquid one. This structure makes all components solid, significantly enhancing safety compared to conventional lithium-ion batteries.

As the performance of solid-state batteries improves, there is a high demand for characteristics such as high capacity, excellent output performance, temperature characteristics, and ultra-longevity. A dedicated battery tester is essential for accurately evaluating these features.

The PFX2731S is a high-rate, multi-channel battery tester designed for charge-discharge testing of single cells in solid-state and lithium-ion batteries. Six channels are built into a single unit, with each channel capable of supporting 6V-20A. This device precisely measures currents ranging from very low to very high.

High-Rate Battery Tester
PFX2731S

10 ms continuous measurement (at the fastest setting)
Supports single cell evaluation (C-rate can be set)
Various charge/discharge modes (9 modes in total)

Charging: CC, CC-CV, CP, CP-CV
Discharging: CC, CC-CV, CP, CP-CV
Pattern charging/discharging: (CC(+CV), CP(+CV))

When an error is found, a built-in path switch immediately terminates the test.
Four thermostatic chambers (produced by Espec) can be operated synchronously
A T-type thermocouple (optional) can be used to measure temperature.
The system can be set up by connecting a LAN cable.
Enhanced protection functions

SD035-PFX BPChecker4000

With the dedicated BPChecker4000 software, the PFX2731S can set and implement conditions for battery charging and discharging characteristic tests and save the test results. BPChecker4000 consists of two programs: Test Condition Editor, which creates test conditions, and Test Executive, which executes the test.

Module Evaluation

The PFX2500 system is an excellent choice for module evaluation of rechargeable batteries. The PFX2512 and PFX2532 can be used with Kikusui’s power supplies and electronic loads to build a charging/discharging system. Therefore, customers who already have our power supplies and/or electronic loads* can create such a system by simply purchasing the PFX2512/ PFX2532.

*To learn more about system lineup, please see product pages.

In addition to various charge/discharge modes, this system also supports sequence and I-V operations. It has a high-performance shunt resistor built in, achieving high-precision measurements of voltage and current with an accuracy of 0.1mV/0.1mA. It can also measure cell voltage and temperature. By using an optional measurement board, an alarm function can stop the device if there is a voltage imbalance among the cells.

On-Site Conditions Can Be Reproduced

The PFX2512 and 2532 can seamlessly charge and discharge by simultaneously controlling the power supply and electronic load. These devices can also conduct IEC62660 tests and BEV cycle life tests. Furthermore, tests can be performed in synchronization with a thermostatic chamber, enabling evaluations under conditions that closely resemble the real-world environment.

Charge/Discharge System Controller

Capable of seamless charging/discharging (high-speed charging/discharging transfer control)
Can accurately measure not only voltage and current but also integrated capacity and electric power
Built-in 10,000-step pattern charge/discharge function
Supports temperature measurement, enabling temperature monitoring during charging and discharging
High-speed sampling of up to 1 ms (maximum of 6000 ppt)
The new 6V range allows for high-precision measurements.
Safety features include overcharging protection based on voltage, electricity, and temperature.
A seismic sensor detects tremors and vibrations and turns off the output to prevent battery damage.
LAN included as standard

Pack Evaluation

The PXB series of bidirectional DC power supplies is an excellent choice for charging and discharging batteries ranging from 10 kW to 200 kW. This series has a large output capacity of 20 kW in a compact 3U chassis. It also supports a maximum voltage of 1500 V for both power and regeneration. The SEAM Mode enables seamless switching between charging and discharging and suppresses current overshooting.

●Regenerative function (on-premises) contributes to carbon neutrality
Power is regenerated from the battery and sent to the main unit. Then, it is converted and regenerated to the AC LINE. Therefore, the system can contribute to carbon neutrality by reducing power consumption and exhaust heat. Regenerative efficiency is 90% (TYP, at rated load).

*The PXB series is designed for on-site power regeneration. Please use it in an environment where the power on the premises is greater than the regenerative power.
*Please contact your nearest sales office for system upgrades.

Furthermore, to evaluate safety, insulation resistance and withstand voltage tests must be conducted between the positive terminal and the case as well as between the negative terminal and the case. The TOS9300 series can sequence these tests, contributing to the efficiency of the production line inspection process.

Bidirectional High-Capacity DC Power Supply
PXB Series

Specifications

High power density: 20 kW in 3U
A single unit supports both power and regeneration
Rated output voltage: 50 V/ 250 V/ 500 V/ 1000 V/ 1500 V
Up to 25 units (500 kW) can be operated in parallel
LAN, USB, RS232C, external analog control (isolated type) included as standard
Regenerative function (on-site)
External control I/O is standard for both NPN and PNP type PLCs

Electrical Safety Multi-Analyzer
TOS9300 Series

Specifications

All-in-one model is now available (TOS9303LC)
Models with partial discharge function can conduct insulation diagnosis (TOS9301PD)
Thanks to the newly developed amplifier, models equipped with a ground continuity test can test both AC and DC ground continuity of up to 40 A.
Dielectric breakdown detection sensitivity can be set.
Withstand voltage test feature for 5kV/100mA AC and 7.2kV/100W DC
Contact current, protective conductor current, and patient leakage current can all be tested (TOS9303LC)
LAN/USB/RS232C included as standard

Reuse (Repurpose) & Recycle

Rechargeable batteries are used in various applications. However, the increasing popularity highlights the need to effectively reuse and recycle the large quantities of rechargeable batteries that are being produced.

For example, when reusing an automotive battery pack as a stationary storage battery, it is necessary to assess the battery’s deterioration by evaluating its charge/discharge rate characteristics, impedance, and cell balance.

In addition, before batteries are disposed of and materials such as rare metals are extracted and recycled, they must first be completely discharged. Kikusui charge-discharge test systems and electronic loads allow for efficient evaluation of the recycled and reused batteries.

20kW rated power in 3U
Maximum operating voltage of 1500 V
Operating modes: CC, CR, CV, CP
Up to 25 units (500 kW) can be operated in parallel
Equipped with a touch panel display
Pre-charge function
I-V characteristic function
Sequence function
LAN, USB, RS232C, external analog control (isolated type) as standard
Regenerative efficiency of over 90% (on-site regeneration)

Capable of seamless charging/discharging (high-speed charging/discharging transfer control)
Can accurately measure not only voltage and current but also integrated capacity and electric power
Built-in 10,000-step pattern charge/discharge function
Supports temperature measurement, enabling temperature monitoring during charging and discharging
High-speed sampling of up to 1 ms (maximum of 6000 ppt)
The new 6V range allows for high-precision measurements.
Safety features include overcharging protection based on voltage, electricity, and temperature.
A seismic sensor detects tremors and vibrations and turns off the output to prevent battery damage.
LAN included as standard