Battery Cell/Module/Pack/BMS Tester

In the automotive sector, batteries are the technological core of electric vehicles (EVs). Their structure is organized into three main levels: cells, modules, and battery packs, each playing a specific role in energy storage and management.

Cells

The cell is the basic storage unit. The most common in automotive applications are lithium-ion cells, available in three main formats: cylindrical, prismatic, and pouch. Each cell consists of an anode (typically graphite), a cathode (often based on metal oxides like NMC – nickel, manganese, cobalt), a liquid electrolyte, and a separator. A cell’s performance depends on parameters such as energy density (Wh/kg), specific power, cycle life, and thermal safety.

Modules

A module is a group of cells connected in series and/or parallel, enclosed in a mechanical structure that ensures integrity and thermal management. Modules include sensors to monitor temperature, voltage, and current, and often feature cooling systems (air or liquid). The electrical configuration of the modules determines the overall voltage and capacity of the battery pack.

Battery Pack

The battery pack is the assembly of multiple modules, integrated with a management system called the BMS (Battery Management System). The BMS is essential for:
Balancing cells during charge/discharge
Preventing overvoltage, short circuits, and overheating
Optimizing battery life and performance
The battery pack is designed to withstand shocks, vibrations, and extreme environmental conditions. It also includes advanced cooling systems and, in modern vehicles, heating systems to ensure optimal performance even at low temperatures.

From a technical standpoint, the main challenges are:

• Energy density: increasing range without adding weight or volume
• Safety: preventing phenomena like thermal runaway
• Durability: ensuring thousands of charge/discharge cycles with minimal degradation
• Recyclability: designing batteries that are easy to disassemble and recycle
• A complete range of solutions for testing automotive components and battery packs

A complete range of solutions for testing automotive components and battery packs

Description

Assing is fully equipped to design and implement the complete range of testing applications for battery systems within the automotive sector. With a deep-rooted expertise in this field, Assing offers end-to-end solutions that address the evolving and complex needs of the electric mobility industry.

From the initial stages of battery system verification and validation to the final phases of certification and quality assurance, Assing provides highly specialized equipment and integrated platforms tailored to meet the rigorous standards of automotive manufacturers and suppliers.

These solutions include automated test benches, end-of-line testing systems, environmental and stress testing setups, and diagnostic tools capable of simulating real-world operating conditions for both cells and complete battery packs. In addition to the development of testing technologies, Assing also excels in the design and construction of controlled environments, such as dry rooms and climate chambers, which are essential for the safe and precise handling of battery components.

These facilities are engineered to maintain ultra-low humidity levels and stable temperature conditions, ensuring optimal performance and safety during the assembly and testing of lithium-ion batteries.