NEWARE Energy Storage Battery Testing Equipment

Cell Screening. Incoming large-format cell quality verification: OCV measurement for SOC estimation and self-discharge screening, ACIR measurement (3mΩ–300Ω) for internal defect detection, dimensional and visual inspection. Statistical lot acceptance with tight consistency bands — critical for ensuring uniform performance across thousands of cells in utility-scale ESS packs.

Capacity / Resistance Matching. High-precision capacity measurement and DCIR characterization for cell binning. Capacity tolerance ≤±0.5% and DCIR grouping within 0.3mΩ bands ensure uniform aging behavior across the pack. Multi-step CC/CV protocols with temperature compensation. Critical for achieving consistent performance in large ESS systems with hundreds of cells in series.

Module & Pack Assembly Verification. Post-assembly module and pack characterization: capacity verification at module level, busbar resistance validation, insulation resistance testing, and BMS communication check. Individual cell voltage monitoring (0~6V, ±0.5mV) and temperature sensing (8CH NTC) confirm assembly quality. Parallel and series configuration validation for ESS rack integration.

Long-Term Cycle & Calendar-Life Evaluation. Ultra-long cycle life testing under representative ESS operating profiles: daily charge-discharge cycling at 0.5C–1C, partial state-of-cycle (PSOC) operation, and elevated temperature aging. Automated periodic capacity check (PPC) with dQ/dV analysis for degradation mode identification. Calendar life testing at various SOC and temperature conditions to model 15–20 year field performance. Energy-regenerative architecture keeps operating costs manageable over thousands of cycles.

SOC/SOH & Thermal-Safety Validation. SOC estimation algorithm validation through cycling data — ampere-hour counting, OCV-SOC lookup, and EKF-based methods. SOH tracking via capacity fade and impedance growth curves. Thermal safety testing per IEC 62619, UL 9540, and GB/T 36276: overcharge, external short circuit, forced discharge, thermal runaway propagation, and fire safety assessment. Environmental chamber linkage for temperature-coupled electrical testing (-40°C to +85°C).

BMS/PCS Communication & System Verification. Comprehensive BMS testing: CAN/RS485/Modbus protocol verification, cell balancing strategy validation, SOC/SOH algorithm accuracy, over/under-voltage and over-current protection. PCS communication and DC source simulation for grid-tied ESS validation. Rack-level integration testing with high-voltage pack cycler (up to 3000V) for full-system performance verification. HVIL detection and insulation monitoring validation.

Field Qualification. Comprehensive data review and compliance report compilation per IEC 62619, UL 9540, GB/T 36276, and grid connection requirements. Final qualification for volume production with full traceability documentation. EOL (End-of-Line) testing protocol setup for production-line integration — safety + performance in a single pass with barcode traceability and MES/LIMS data management.