The Challenge
A Southern California E-Bike (Electronic Bike) manufacturer approached us regarding a system to test and validate their E-Bike battery pack assembly.
The Solution
Using our BatteryFlex propriety testing software and PXI data acquisition platforms, we custom-designed a fixture meeting our client’s needs and product specifications for improved quality assurance of their E-Bike batteries. This has improved our client’s warranty return rate by 12%.
Background
The explosion of E-Bikes in the last few years has enabled people to go the extra mile. With assisted pedaling to full assisted riding, e-bikes combine the benefits of being active with a rechargeable battery that maintains integrity over thousands of charges.
A Southern California E-Bike manufacturer approached us regarding a system to test and validate their E-Bike batteries. Their undesirable level of battery malfunctions and warranty returns prompted them to seek a solution for the testing of their E-Bike batteries.
Left: PXI data acquisition platform. Right: BatteryFlex LabVIEW user interface (UI) showing live test data
Upon customizing our BatteryFlex platform to our customer’s needs, we began to run overnight tests of 8+ E-Bike batteries. They are simultaneously loaded into the BatteryFlex fixture and with detailed test reports generated by morning. We performed the following tests for a pass or fail test according to the customer’s specifications:
Open Circuit Voltage (OCV)
Power Cycle Test
Capacity (Static, Script, Pattern/Pulse)
DC Internal Resistance (DCIR)
AC Internal Resistance (ACIR)
A pass validated the battery’s function for integration into the final product whereas a failure prevented a faulty battery from reaching the customer. Using the BatteryFlex platform increased the accuracy of the client’s voltage and current measurement of their outsourced Lithium-Ion batteries.
BatteryFlex Offerings
High-Resolution, High-Speed Measurements
PXI Platform
Playback and Record Load Cell Scenarios
Data Logging, Analysis, and Storage
Output to any format report or datasheet
Thermal Monitoring and Measuring
Safety Interlocks and Shutdown
Delivering the Outcome
Our BatteryFlex platform allows for the accurate test and measurement of our customer’s outsourced E-Bike batteries ensuring a faster speed-of-test and improved quality assurance. Our automated fixture identifies the individual capacity of each battery cell undergoing simultaneous testing to determine if they are a pass or fail according to the customer’s specifications. We have improved our customer’s E-Bike battery warranty return rate in active partnership by 12%. We also provided a proof of concept developed into a complete test fixture deployed at our customer’s headquarters within a 10-week timeline.
Battery Flex PXI Card Specifications
4-Quadrant SMU (±60V, ±3A, 100fA Meas)
7.5 Digital Multimeter (±3A, 1.8MS/s)
Thermocouple or RTD Measurement
Serial, CAN, I2C, SPI Communication
PXI Modular Architecture for flexibile Instruments, Channel, & I/O Count
Datasheet and Battery Flex Overview
BatteryFlex Datasheet for Download