Tektronix in the 2024 North American Battery Show: Leading the Future of Battery Testing, Results, and Growth

​

The North American Battery Show brings together engineers, business leaders, top-industry companies, and innovative thinkers to discover ground-breaking products and create powerful solutions for the future. Tektronix showcased our complete suite of solutions for the battery industry, from initial R&D through to production and recycling.

Throughout the show we demonstrated our solutions in:

• Cell Characterization
• Busbar Weld Resistance
• High-Power Power Supplies for Battery Testing
• High Bidirectional Power Density
• Turnkey Battery Testing and Cycling at Volume

Cell Characterization

At demo station #1 we highlighted Cell Characterization. Cell characterization includes measuring the defining parameters of a battery and cycling the cell to identify how parameters change over the lifetime of the battery. Parameters may include Open Circuit Voltage (OCV), Internal Resistance (ESR), and energy capacity. Battery Cells need to be characterized at numerous points: During development of new cells, engineers will characterize a cell numerous times to understand its performance. When integrating battery-powered systems, an end customer may characterize purchased cells either to verify the performance in the cell datasheet, or to validate their performance under a unique use case. During production, individual cells may be spot checked in a production lab. Characterization is made easy with the Battery App of Keithley KickStart and a SMU and optionally a DMM for enhanced precision.

Equipment used: Keithley 2450, DMM7510, Keithley Kickstart

Busbar Weld Resistance

At demo station #2 we showcased our solution for measuring Busbar Weld Resistance. Battery systems are made of individual battery cells combined in series and parallel into modules, then those modules into packs. Modules are joined with a piece of low resistance metal called a busbar. The welds that join individual cells and modules together and to the busbar represent a point of failure, especially for demanding high-current applications like EVs. The combination of a Keithley 3706A and high current Source Measure unit allows fast, accurate resistance measurements across hundreds of channels; while the 3706A is also capable of taking temperature measurements.

Equipment used: Keithley: 3706A, 2460 SMU or 2461, 2 Series scope

High-Power Power Supplies for Battery Testing

At demo station #3 we featured High-Power Power Supplies optimized for battery testing. Battery systems frequently need to be cycled to determine their health or measure other parameters. The EA-BT 20000 Series is optimized for battery cycling thanks to its bidirectional capability that can source and sink power from a single output. The high power density and triple channel model reduce the footprint required and can easily allow cycling or testing of multiple modules at the same time.

Designers of systems that use batteries might want to use a battery emulator during development and testing so they don’t have to manage a large pool of batteries. The 20000 Series is also capable of simulating batteries at full power. 

Equipment used: EA-BT 20000 Triple

Highest Bidirectional Power Density

At demo station #4 we featured the EA 10000 Industrial Series which offers the highest power density available: up to 60kW of sourcing/sinking in a compact 6U chassis and up to 360kW in one rack. This high-density solution is ideal for applications involving large battery systems, where space and power efficiency are critical. The bidirectional capability allows for efficient charging and discharging of batteries, making it a versatile tool for energy management in various high-power applications. By paralleling 64 devices together in multiple racks, 3.84 MW at 64,000 A can be achieved.

Equipment used: EA 10000 Series Industrial 6U

Turnkey Battery Testing and Cycling at Volume

At demo station #5 the EA-BTS 10300 Series took the stage, it provides a comprehensive turnkey solution for high-volume battery testing and cycling. With its compact design and integrated control features, this system is optimized for large-scale battery testing operations, ensuring efficient and precise testing processes. Made up of a series of Elektro-Automatik supplies tied together with a custom control system and operated by a new, widget-based UI that’s been designed for ease-of-use, the EA-BTS 10300 Series is engineered to handle the demands of production environments, offering unparalleled control and efficiency compared to competitors.

Equipment used: EA-BTS 10300

Conclusion

On-going research and development of more sophisticated and safer battery technologies continue at a rapid pace. Both new battery technology and expanding the charging infrastructure has remained strong. Established EV companies are also exploring ways to remain competitive against lower cost competitors, including investment in advanced battery technology such as solid-state batteries and pivoting to more hybrid vehicles in their line-up. Whatever issue you’re working on, Tektronix is ready with test solutions to help you excel.