Many electric products depend heavily on the power density and reliability of their battery packs, making battery performance testing a crucial part of development and validation.  Designing test plans that accurately reflect real-world conditions presents several challenges.  For example, varying driving conditions place different levels of strain on electric vehicle batteries, while power-hungry smartphone apps require high computational demands and drain battery life more quickly.  As consumers want and expect higher performing electronic products, the demand on the battery capacity and performance increases.

At MGA Research Corporation, we offer performance testing that helps our customers identify research and development opportunities and ensure their products operate at full potential. With over 30 years of experience, we understand the importance of delivering high-quality results safely and collaborating closely with our customers to provide flexibility while meeting tight deadlines.

As part of this commitment, we offer a range of performance tests designed to evaluate aspects of battery functionality. The tests listed below can be performed individually or as part of a Reference Performance Test (RPT) to evaluate battery functionality before and after durability testing:

·        SAE J1798 Capacity Check

·        Hybrid Pulse Power Characterization (HPPC)

·        High and Low-temperature operation (HTOE and LTOE)

·        Cycle Life and many others.  

By combining both electrical and mechanical testing, our team provides an integrated in-house solution to many test plans. Additionally, our expertise in fixture fabrication and UN 38.3 sets a strong foundation for all testing.

 Battery Capacity

Battery capacity is a critical characteristic in understanding overall battery health.  In a real world scenario, a vehicle BMS (Battery Management System) is constantly analyzing battery data such as temperature, SOC, charge/discharge cycles to evaluate battery capacity and alert the driver to any possible issues present or upcoming needs for maintenance. While in development, battery capacity testing is used not only to predict the life of the battery, but also to identify damaged cells and other faults that may be present.  This information can then be used to create more robust designs and longer lasting battery systems.

SAE J1798 Capacity Check

Performed at the cell, module, and pack levels, the SAE J1798 Capacity Check utilizes either constant current or constant power. The battery is then charged and discharged through its entire range of operation. Our facilities have a variety of coolant chillers and large climatic chambers to maintain battery temperature at a standard 25°C as well as a variety of other temperatures. Maintaining the target ambient temperature is key for an accurate measurement of a battery’s full capacity.

‍

Hybrid Pulse Power Characterization (HPPC)

Batteries undergo various dynamic conditions in the real world, such as acceleration and braking, which are both affected by the battery’s ability to absorb and deliver power efficiently.  Like capacity testing, HPPC testing is used to evaluate overall battery performance and understand power limits.  The data collected is also used to develop models used by the BCM for predicting battery life and managing power delivery.

The HPPC test determines the dynamic power capabilities at different States of Charge (SOC). While the pulses are similar to other tests, such as the peak power test, these standard tests multiple SOC levels with both discharge and regeneration. HPPC  is referenced in specifications such as ISO 12405 and the FreedomCAR USABC Battery Test Manual.

 Customization of this test is common, and we can tailor the fixturing, temperature data acquisition, climatic chamber profile, and battery cycler profile to meet the exact R&D needs.

Cycle Life

Cycle life testing is used to evaluate the long-term performance and durability of battery systems. Essentially, drive profiles along with fast charge and fast discharge profiles are performed to simulate vigorous driving on individual cells, modules, or battery packs.

For battery pack performance testing, monitoring may include coolant temperature, flow rate, and pressure for the cooling circuit, in addition to CAN data. By working closely with our customers, all these parameters can be collected and monitored throughout testing. At the module and cell level, MGA has extensive data acquisition systems for temperature thermocouples and cell voltage.

During the battery cycling process, the sample temperature and changes in internal resistance are monitored. After a predetermined number of cycles, a reference profile test is executed.

How MGA Supports Battery Performance Testing

Battery performance testing ensures EV range, reliability, and safety. Using ISO 17025–accredited equipment and decades of expertise, MGA delivers precise results to develop next-generation battery systems. Our in-house battery cyclers, available at our Michigan, Wisconsin, and New York facilities, support all battery sizes and applications.

With expectations of longer battery life, extended range, and more powerful performance, battery suppliers face increasing pressure to innovate. Understanding how these developments impact the lifetime performance of a battery pack or cell is essential for the final product. MGA Research Corporation assists customers in developing and implementing battery performance test plans, supporting the progress of battery technology into the future.

For customers needing short-term solutions, our upcoming article will highlight our new battery cycler rentals to support in-house testing programs. If you are ready to advance your battery performance testing, please fill out our contact form. We look forward to working with you!

‍