Battery Test Coverage for Lab and Production

Project Summary

A medical device manufacturer achieved 100% quality verification in 12 weeks by implementing an automated battery-testing solution built with Cyth BatteryCheck and NI PXI.

System Features & Components

• NI PXI data acquisition platform provided high-accuracy voltage and current measurements to enable comprehensive battery characterization

• BatteryCheck mixed-measurement testing architecture enabled simultaneous test of multiple batteries to maximize testing throughput

• LabVIEW user interface provided operators with live test data visualization

• Scalable platform architecture accommodated increased production volumes without additional capital investment

  
  

Outcomes

• 100% individual battery verification achieved, eliminating field failures due to battery capacity issues

• Test cycle time and cost of test were significantly reduced through parallel test of multiple batteries

• Turnkey automated test solution delivered in 12 weeks, leveraging Cyth BatteryFlex platform

Technology at-a-glance

• NI PXI platform

• LabVIEW software

• BatteryFlex ATE platform

Verifying OEM Component Performance

When designing new products, manufacturers must verify that every component in the bill of materials (BOM) performs to OEM specifications, ensuring that the product delivers on promises made to end-users.

Some components influence a device's overall performance more than others. For example, a defective or substandard battery built into a in a life-critical application can result risks to patient safety and an enormous liability burden for the device manufacturer.

Manual Testing Limits Scalability

The device manufacturer’s manual battery testing methodology was not capable of addressing their quality assurance needs.

• Measurement accuracy limitations prevented the acquisition of the high-precision voltage and current measurements necessary for comprehensive battery characterization.

• Testing inefficiencies of manual processes created bottlenecks in production timelines.

• Quality uncertainty resulting from the lack of individual battery verification resulted in deployment risks for life-critical applications.

• Scalability constraints of manual testing prevented the manufacturer from increasing production volumes.

  
  

To hold their supplier accountable and ensure patient safety, the device manufacturer needed a high-accuracy, automated solution to verify the quality of the batteries built into their portable ventilators. They decided to partner with Cyth Systems to address their automated testing needs because of their proven expertise designing high-throughput automated test solutions.

Comprehensive Battery Characterization

Cyth deployed their BatteryCheck architecture, an automated battery testing platform for comprehensive battery characterization leveraging the high-accuracy measurement capabilities of NI’s PXI platform. The programmatic execution of numerous test protocols simultaneously across multiple batteries enabled the device manufacturer to drive test time and test cost down substantially.

Key hardware capabilities:

• NI PXI data acquisition for high-accuracy voltage and current measurements

• Cyth BatteryCheck multi-channel architecture enabled simultaneous battery testing

• Custom test fixtures ensured a secure battery connection and consistent test conditions

Key software capabilities:

• LabVIEW-based user interface for live data visualization

• Automated test sequencing for five critical battery characterization protocols

  • Open Circuit Voltage (OCV)

  • Power Cycle Test

  • Capacity Testing (Static, Script, Pattern/Pulse)

  • DC Internal Resistance (DCIR)

  • AC Internal Resistance (ACIR)

• Battery capacity identification and quality verification for each individual battery

100% Quality Verification

The turnkey test solution transformed the device manufacturer’s battery quality assurance from a manual bottleneck into an automated, scalable process.

• Quality assurance: 100% individual battery verification prior to deployment eliminated field failures from battery capacity issues

• Testing efficiency: Simultaneous testing of multiple batteries substantially reduced cycle time and overall cost of test

• Production flexibility: Scalable platform accommodates increased testing volumes without additional capital investment

• Risk mitigation: High-accuracy measurements ensure that only specification-compliant batteries are deployed into life-critical ventilators

• Rapid deployment: BatteryCheck reference design accelerated solution development time; everything from proof of concept to a turnkey test system was deployed in 12 weeks.

Now, the medical device manufacturer operates with confidence, knowing that every single battery deployed into their portable ventilators meets their exact capacity specifications, ensuring reliable performance in life-critical patient care.