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

1. Equipment Overview

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.

3. Technical Specifications

3.1 Module/PACK Compatibility

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

Size Range:

Minimum: 300 × 200 × 50 mm.

Maximum: 1,500 × 1,000 × 300 mm.

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

3.2 Electrical Testing Parameters

Voltage Testing:

Range: 0–1,000 V.

Accuracy: ±0.05%.

Current Testing:

Range: 0–500 A.

Accuracy: ±0.1%.

Capacity Testing:

Range: 0–1,000 Ah.

Accuracy: ±0.1%.

Internal Resistance Testing:

Range: 0.01–50 mΩ.

Accuracy: ±0.05 mΩ.

3.3 Functional Testing

Key Parameters Evaluated:

Overvoltage/undervoltage protection.

Overcurrent/short-circuit protection.

Temperature monitoring performance.

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

Insulation resistance and dielectric strength.

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

3.4 System Capacit.

Parallel Channels: 8–32 channels (configurable).

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

3.5 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

3.6 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.

3.7 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.

3.8 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.

3.9 Power Requirements

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

Power Consumption: ≤120 kW.

3.10 Environmental Requirements

Operating Temperature: 15–35°C.

Humidity: ≤70% RH (non-condensing).

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

4. Applications

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.

5. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspect connectors and test interfaces.

Monthly: Verify calibration of testing instruments.

Annually: Comprehensive diagnostics and system updates.

Warranty:

Standard: 1 year.

Extended: Optional packages available.