Category: Battery Test Equipment

A123 Systems Selects NH Research 9200 Battery Test Systems for Module and Pack Testing

Testimonial Statement from Tony Gambrel, Director of Test Operations – A123 Systems

“The NHR 9200 battery test systems are flexible, reliable and cost effective. The ability to configure single 9200s, or multiple 9200s, for either multiple low power channels or a single high power channel gives us greater flexibility and efficiency in our test scheduling.

A123 Systems set up of NHR Battery Test System - NH Research (NHR)

Figure 1 – NHR 9200 Battery Test Systems at A123 Systems R&D Laboratory

This flexibility has allowed us to perform more of our testing in-house saving us time and money. The power ratings and voltage range of the 9200s allow us to fulfill all of our module, 48V pack and 12V pack testing requirements.

NHR test equipment is very dependable. Our testing requires 24/7 operation and the NHR units have done this with zero downtime. The slew rate capability of the units allows us meet the response-demand and accuracy of our customer drive cycles as well as giving us the capability of performing some specialty testing in-house.

The compact footprint and easy electrical connection make installation of the units very easy. The interface to our external test and monitoring systems was user-friendly, simple and stable. The modularity of the load units adds to the ease of servicing.

A123 Systems set up of NHR Battery Test System - NH Research (NHR)

Figure 2 – NHR 9200 Battery Test Systems (back side of test equipment) at A123 Systems R&D Laboratory

The NHR team has been very responsive and delivered on all of the timing requirements. The sales team was responsive without being high pressure. In the early part of the project they were quick to provide technical information and worked well with us in the final specification and quoting stages. The service/training team was very knowledgeable with the product and worked well with our team during the updating and training processes. All of the deliveries were made on time and without damage or issue.”

– Tony Gambrel, Director of Test Operations A123 Systems

Download “A123 Testimonial” Article

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Testing Electric Vehicles Using Battery Emulation

Testing Electric Vehicles with Battery Emulation - NH Research (NHR)

Today, next generation battery emulation provides a competitive advantage for testing electric vehicle (EV) components and systems. Battery Emulation is ideal for testing the electric powertrain, DC fast charging and other EV applications in which a battery is required for testing.

Using batteries as power sources for testing is an extremely time-consuming and costly challenge across the transportation electrification industry including EV, aerospace, and e-mobility markets. The transition from traditional to modern electrification architectures, require flexible and scalable testing methodologies. Testing with batteries can delay projects, increase safety risks and hinder engineering productivity. As electrification is evolving to higher power demands, the ability to emulate a battery or energy storage systems with speed and accuracy is critical. Battery emulation can substantially reduce test time, energy consumption and operating costs.

Battery Emulation Testing vs. Real Battery Testing

There are 3 key benefits to testing electric vehicles with battery emulation or battery simulator testing, rather than using a real battery. Battery emulation dramatically reduces testing time, provides highly repeatable test results, and creates a safer test environment. This results in preparation time, operator errors, and result variations due to battery temperature or aging, being eliminated.

Testing EVs with Battery Emulation Reduces Testing Time

Testing a real battery often requires operator preparation for each step. Batteries must first be charged, or discharged, then allowed to rest, and finally tested. The significant battery preparation time can be avoided by using an emulated battery. Emulation can reduce total test times by more than 70%.

Battery Emulation Provides Repeatable Test Results

Over time, batteries provide inconsistent test results, wear out, and need to be replaced. Battery age, internal temperature, and cycling are all contributing factors to the limited battery life-span. Manual battery operation, including rest time facilitation, can also cause inaccurate test results. Battery emulation provides consistent and repeatable test results, unlike those from real battery testing, during which battery changes and operator errors cause variations in test results.

Battery Emulation Improves Safety

Although batteries are generally safe when operated within normal operating ranges, they are high energy devices that may pose serious risks upon battery or unit under test (UUT) failure. Such risks include exposure to dangerous gases, fires, explosions, or corrosive chemicals. These concerns have led to safety policies stating that tests must be conducted and monitored during working hours. Furthermore, testing extreme cases of over-discharged or over-charged batteries can pose unpredictable risks and safety hazards. Battery emulation creates a safe testing environment without any of the concerns that arise when real batteries are used. Also, emulation safely verifies UUT behavior when a battery is outside a normal operating condition.

Not all Battery Emulators are Created Equal

While testing with real batteries is possible, it can seem quite impractical. Using battery emulator or battery simulator testing produces test results faster, provides a consistent test, and can safely test power electronic devices that typically require a real battery.

However, not all battery emulators, regenerative DC sources and DC common bus architectures are optimally designed to provide accurate and timely results. There are key technology considerations when selecting a battery emulator for your application. Contact us to learn what battery emulation capabilities are the right approaches for faster, scalable and more repeatable testing.

View Electric Vehicle Test Solutions

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NHR Presents Live Webinar: The Fundamentals of Battery Test, on April 29th.

EV Batteries - NH Research (NHR)

NH Research Inc., a leading provider of power electronics and battery test solutions for the automotive, industrial, energy storage, and critical-power markets, will be hosting a free live webinar on The Fundamentals of Battery Module and Pack Test on April 29th, 2020.

In this live webinar, Martin Weiss, Product Director at NHR, will discuss key industry trends impacting battery test, current challenges and opportunities, and key factors in selecting the right test approach. This session will cover the fundamental concepts and key considerations for module and pack battery testing.

Webinar Description:
The battery market is growing rapidly due to the acceleration of electrification in the automotive, aerospace and energy industries. In turn, batteries have become the pivotal component for electrifying cars, planes, trains and automobiles and storing clean energy. Therefore, it’s imperative that today’s engineers, researchers, and managers understand the fundamentals of how to test batteries as well as the most productive approaches to ensure product performance, safety and time to market.

Battery pack and module testing is becoming more critical than ever. Today, engineers face new challenges including increased complexity of the tests and set-ups, long development and test times, addressing safety requirements and avoiding hazards. Furthermore, testing to the application requires emulating real-world conditions by reacting to CAN, BMS and other communication protocols.

In this series, learn about:

  • Industry trends impacting battery test
  • The fundamentals of battery module/pack testing
  • How to reduce time to market and improve engineering productivity
  • Next generation solutions for battery test

Webinar Event: The Fundamentals of Battery Module and Pack Test
Dates: Wednesday, April 29, 2020 at 2-3pm EDT

Register now: https://nhresearch.com/landing/landing-webinar-registration-form/

For more information on our Battery Test Solutions, visit our application page.

About NH Research

NHR enables electrification by accelerating innovation, validation and functional testing of today’s technologies. Backed by over 50 years of experience in power conversion and power electronics test systems and instruments, our test solutions deliver the performance, simplicity, and safety that engineers and researchers in aerospace, defense, automotive and energy industries require.

For more information, visit www.nhresearch.com.

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