ESS Battery Module PACK End-of-Line (EOL) Testing System

The ESS Battery Module PACK End-of-Line (EOL) Testing System is a comprehensive solution for validating the final quality and performance of energy storage system (ESS) battery modules and PACKs. Designed to simulate real-world operational scenarios, this system ensures each module or PACK meets stringent industry standards before deployment. The system supports high-accuracy testing, data analysis, and efficient testing workflows for large-scale production environments.

1. Module/PACK Compatibility

· Supported Formats: Prismatic, pouch, and cylindrical module/PACK configurations.

· Size Range:

o Minimum: 300 × 200 × 50 mm.

o Maximum: 1,500 × 1,000 × 300 mm.

· Weight Capacity: Up to 200 kg per module/PACK.

2. Electrical Testing Parameters

· Voltage Testing:

o Range: 0–1,000 V.

o Accuracy: ±0.05%.

· Current Testing:

o Range: 0–500 A.

o Accuracy: ±0.1%.

· Capacity Testing:

o Range: 0–1,000 Ah.

o Accuracy: ±0.1%.

· Internal Resistance Testing:

o Range: 0.01–50 mΩ.

o Accuracy: ±0.05 mΩ.

3. Functional Testing

· Key Parameters Evaluated:

o Overvoltage/undervoltage protection.

o Overcurrent/short-circuit protection.

o Temperature monitoring performance.

o SOC (State of Charge) and SOH (State of Health) accuracy.

o Insulation resistance and dielectric strength.

· Cycle Testing: Supports multiple charge/discharge cycles to simulate long-term operation.

4 System Capacity

· Parallel Channels: 8–32 channels (configurable).

· Testing Throughput: Up to 20 modules or PACKs per batch (depending on size and configuration).

5. Data Management

· Real-Time Monitoring: Tracks voltage, current, resistance, and thermal behavior during tests.

· Traceability: Unique ID tracking for each module/PACK.

· Data Logging: High-resolution data storage for performance analysis and fault diagnosis.

· Reporting: Automated generation of customizable test reports.

· Integration: Compatible with MES/ERP systems for centralized monitoring and analysis.

6. Control System

· HMI: 12-inch touchscreen for user-friendly operation.

· Software: Advanced testing software with customizable profiles and real-time monitoring.

· Communication Protocols: CAN, RS485, RS232, and Ethernet for interfacing with BMS.

7. Safety Features

· Electrical Protection: Overcurrent, overvoltage, and short-circuit protections.

· Thermal Monitoring: Alerts for overheating or thermal deviations.

· Emergency Shutdown: Physical and software-activated emergency stop functions.

· Fire Suppression: Optional fire suppression system for high-capacity modules/PACKs.

8. Mechanical Design

· Dimensions: 2,500 × 1,500 × 2,200 mm (customizable).

· Weight: Approximately 3,000 kg.

· Cabinet Structure: Modular design for efficient testing and maintenance.

· Cooling System: Integrated forced-air cooling or optional liquid cooling for high-capacity tests.

9. Power Requirements

· Input Voltage: AC 380V ±10%, 50/60 Hz, 3-phase.

· Power Consumption: ≤120 kW.

10. Environmental Requirements

· Operating Temperature: 15–35°C.

· Humidity: ≤70% RH (non-condensing).

· Environment: Clean and dust-free area recommended for optimal operation.

· Energy Storage Systems (ESS): Final validation for battery modules and PACKs used in grid stabilization and renewable energy storage.

· Commercial and Industrial ESS: Ensures compliance with quality standards for large-scale deployments.

· Renewable Energy Integration: Tests modules and PACKs designed for solar and wind energy storage systems.

· Maintenance Schedule:

o Weekly: Inspect connectors and test interfaces.

o Monthly: Verify calibration of testing instruments.

o Annually: Comprehensive diagnostics and system updates.

· Warranty:

o Standard: 1 year.

o Extended: Optional packages available.