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Electric Vehicle Battery Testing – A New World of Challenges
电动汽车电池片、模块和电池组生产系统依靠精密的电气仪器来可靠地识别变化。制造商依靠价格合理的测试设备：
- 持续检测微小的电气异常
- 集成到复杂多样的自动化系统中
- 随着测试要求的变化而调整
- 实现零停机
Test engineers are working closely with R&D engineers to bring new battery technologies to reality. And engineers trust Keithley electric vehicle testing equipment to help them to push the boundaries.
电动汽车电池技术和关键生产测试
用开路电压测试（OCV）对电池进行分级
电池分级是任何电池生产环境中的一个关键步骤，电池性能是关键。开路电压（OCV）的测量被用来将电池分为以下几个等级。
- Grade A batteries have the longest lifespans, lower internal impedance and better overall performance. Used in high power applications like electric vehicles.
- B级 电池的性能较差，寿命较短。用于储能应用
- C级 电池是性能最低的。用于单电池便携式应用
制造商需要将最高质量的电池与可能存在内部缺陷（例如短路或污染物）的电池分开。电池的OCV可以随着时间的推移进行监测，以观察放电趋势并确定性能特征。这个过程可能需要几周时间来观察OCV在几十到几百微伏的变化。
Keithley’s DMM7510 is a perfect solution for OCV testing in the production environment. Its 7.5 digit measurement resolution and superior accuracy means measuring smaller changes in voltage and getting results sooner. For higher volume applications, the Keithley 3706A System Switch and Multimeter allows for up to 576 two-wire channels in one mainframe, expanding your testing capabilities without sacrificing test rack or bench space.
用电阻测量检查电池片和母线焊缝
焊接是自动化生产系统中的常见做法，用于将电池片连接到电极，以及将完整的电池连接在一起以形成电池组。大型电池组可以有数十到数百个焊缝或接头，将电池连接到母线。
质量好的焊点对电路的阻力很小，通常只有微欧姆。坏的焊缝或接头的测量值在毫欧范围内，这导致了性能问题和过多的热量产生，可能导致严重的热失控事件。几乎不可能从视觉上识别出不良的焊缝。
然而，在生产环境中，通过使用精密DMM（如吉时利3706A系统开关和万用表）和电流源（如吉时利2460 SMU）进行电阻测量，可以快速识别焊接缺陷。SMU可以提供高达7A的精确电流，而DMM测量接头的电阻可低至微欧姆。3706A中内置的高密度开关可实现更多焊接检查，同时减少重新布线。
使用温度数据采集的环境和安全测试
Environmental testing is extremely important to ensure batteries will withstand and perform under extreme environmental conditions. Thermal testing is also an important part of safety qualifications. Although temperature testing varies widely depending on the test sequence, battery type, and physical constraints, common temperature measurements on a battery include:
- 使用嵌入式传感器测量电池或模块的内部温度
- 电池或模块的外部温度
- 监测电池组周围的环境温度以了解散热情况或验证环境条件。
因为电池的性能取决于温度，工程师要测量、记录，在某些情况下还要对电池进行特征描述，并在安装时将其编入电动车。温度也是电池故障和热失控的指标。
吉时利3706A系统开关和万用表是一个高精度的开关系统，每个主机有多达576个2线通道。可定制的开关配置可配置为用于更多监测点的密度或用于快速温度检查的速度。
用开路电压测试量化电池自放电情况
电池在没有连接的情况下，往往会随着时间的推移而放电，因为化学反应在内部慢慢逆转。理想情况下，这种内部自放电电流是非常小的，所以电池可以保持更长的充电时间。有内部缺陷的电池，如微短、分离器上的针孔和污染物，随着时间的推移会比高质量的电池放电更快。
This could cause poor performance and balancing issues in a pack or cause the cell to be stressed. The open circuit voltage (OCV) of the battery can be used to monitor the self-discharge behavior as the open circuit voltage decreases when the battery discharges. Separating the good batteries from the defective batteries before they are placed in a pack can require weeks of monitoring as OCV changes may only be tens to hundreds of microvolts.
Keithley的DMM7510是OCV监测测量自放电的完美解决方案。7.5位数的分辨率和卓越的精度意味着可以更快地测量电压的较小变化和查看趋势。对于更多的应用，吉时利3706A系统开关和万用表允许在一个主机上有多达576个两线通道，在不牺牲测试机架或工作台空间的情况下增强测试能力。
自放电是指即使在电池断开的情况下，离子仍在内部流动。
形成、老化和电池循环
电池制造过程中最重要的部分是形成和老化阶段，在此阶段电池中建立了关键的化学机制。这一过程的结果直接影响到电池以后的性能，并进行成型后测试，以确定未能正确成型的电池。
形成和老化要求电池以不同的速度反复充电和放电。循环电池是许多其他测试中的一个重要组成部分，包括建模和热特性分析。
测试程序差别很大，取决于电池的化学成分、结构和测试概况。而且许多其他测试需要电池循环，所以测试方案必须灵活。
Keithley source measure units or SMUs provide a convenient single box solution for charging and discharging. The 2400 Series Graphical Touchscreen SMUs can accurately source currents up to 7 A DC. These SMUs offer TSP® Scripting Technology to make production automation simple and efficient.
用直流内阻确保电池质量
高内阻的电池性能较低，发生热失控等故障的风险较高。内阻是固体电解质中间层（SEI）形成不正确的指标，也可以作为电池质量的衡量标准。
吉时利源测量单元（SMU）为直流内阻测试提供了一个单箱解决方案。2400系列图形触摸屏SMU可以产生精确的低电流，并测量相应的电压以计算内阻。
使用SMU测量电池单元的直流内阻。
电池单元中的层数。测量电极材料和集电器之间的接触电阻。
适用于超低电阻测量的两个选项
集电器和卷到集电器上的电极材料之间的连接不良会增加电池的内阻。尽早识别不良电极可在生产过程中节省时间和资源。
The Keithley 6200 Series Sensitive Current Sources paired with the 2182A Nanovoltmeter makes the perfect combination for sensitive low resistance measurements on electrodes. This low resistance combination measures as low as tens of nano-ohms for the best confidence in the quality of the electrode.
通过测量绝缘电阻保持蓄电池绝缘
电池短路意味着危险故障的风险短路可能发生在内部，但当绝缘失效或电池组连接不正确时，也有外部短路的风险。验证电池电极与地面的隔离以及暴露在电流中的任何材料的绝缘质量可以防止以后出现严重的故障。
吉时利2470高压源测量单元（SMU）为测量材料的电阻提供了一个简单的单箱解决方案。SMU可以提供高达1kV的电压源并计算出材料的相应电阻。
漏电/绝缘电阻蓄电池的标签应与底盘电气隔离。
Electric Vehicle Battery Testing Equipment
Frequently Asked Questions
What is EV battery testing?
EV battery testing encompasses many methods to verify a battery’s performance and safety. Testing occurs at all stages of the battery lifecycle, from the design labs to the manufacturing floor to the final end user.
How are Electric Vehicle batteries tested?
EV Batteries undergo a wide variety of tests including chemical, mechanical, thermal and electrical testing. Electrical testing includes measuring battery voltage, internal impedance, resistance of components and charge/discharge profiles. Electrical test equipment can be measurement-only like a DMM or require accurate sourcing and measurement in the form of power supplies and source measure units (SMUs).
What is the standard for EV battery testing?
There are many standards available for EV battery testing. Standards encompass safety and performance for batteries starting at the cell level, all the way to the pack level. Standards are also dependent on end use application. For example, standards for consumer electric vehicles may differ from standards for industrial electrical vehicles or small transportation such as E-bikes and E-scooters.
Why is EV battery testing important?
Thorough testing ensures that the batteries are not only safe, but meet the performance specifications set by the manufacturer. Low quality batteries can have compounding effects on the whole pack, so it’s crucial to identify those batteries before they make it to the end user. Testing in the research and development phase is also key to validating new and improved designs.
What are the requirements for EV batteries?
Battery specifications can be complex, with ratings on voltage, current, impedance, capacity and lifespan. Ratings vary depending on the battery chemistry and construction. Electrical testing is necessary to verify these ratings for the end user.