Robots Battery Testing Solution

Cell Screening & Matching. Incoming cells are tested for capacity, internal resistance (IR), and self-discharge rate. Cells are sorted into matched groups to ensure pack uniformity — critical for series-connected robot battery packs where the weakest cell limits overall performance and safety.

Initial Performance Testing. Baseline performance is established through GCD (Galvanostatic Charge-Discharge) at multiple C-rates, AC/DC internal resistance measurement, and initial rate capability assessment. This data serves as the reference for all subsequent aging and degradation analysis throughout the robot`s battery lifecycle.

Rate / Pulse & Dynamic-Load Evaluation. Cells are subjected to high-rate discharge (up to 5C–10C for burst loads), pulse current profiles simulating joint actuation, and arbitrary waveform loading replicating real robot duty cycles — including regenerative braking energy recovery during deceleration. Voltage sag, temperature rise, and energy efficiency are precisely characterized.

Cycle-Life Testing. Batteries undergo thousands of charge-discharge cycles using duty cycle profiles that mirror real robot operation — active work periods, idle standby, and opportunity charging. Capacity fade, impedance growth, and DCIR evolution are tracked to predict field lifetime and determine replacement intervals.

Temperature & Safety Validation. Batteries are tested across the full operating temperature range (–20°C to +60°C for industrial robots), including thermal cycling, humidity exposure, and vibration. Safety validation includes overcharge, over-discharge, short-circuit, and mechanical abuse testing per relevant standards (IEC 62133, UL 2271 for light EV/robot applications).

Pack / BMS Verification. Completed battery packs are tested with the BMS for charge/discharge protection (OVP, UVP, OCP, OTP), cell balancing accuracy, SOC estimation, and communication protocol validation (CAN, RS485, IIC, SMBus). The BMS testing system simulates 24 channels of cell voltages to verify all fault conditions without risking actual battery packs.

Product Qualification. Final qualification testing validates the complete battery system against robot manufacturer specifications — including end-of-discharge cutoff accuracy, communication handshake timing, mechanical fit verification, and compliance with applicable standards (IEC 62133, UN38.3, UL 2271). Production data is archived for traceability and warranty analysis.