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Battery Cycler

EV Battery cyclers for charge, discharge and lifecycle testing of EV battery packs and modules.

Test your high voltage EV battery packs and modules with a Unico EV Battery Cycler.

This remarkable EV battery cycler is designed for high voltage electric vehicle testing procedures that include real-time simulation of battery charging, discharging, periods of high current draw and recharge, energy regeneration and battery degradation, simulated load resistance, and your custom testing profiles.

Features

Testing Applications

Testing of battery charging, discharging, periods of high current draw and recharge, energy regeneration and battery degradation, simulated load resistance, and your custom testing profiles.

Precision Control and Flexibility

Unico inverters with Silicon IGBTs produce high slew rates, so there is no overshoot and zero crossing delay. The digital control loops can accurately track all command targets, including constant, ramping, and varying levels. Seamless Mode Switching makes on-the-fly toggling between control modes simple and safe. Configure with an optimized output filter based on the application.

Common DC bus architecture allows for add-on dynamometer controls sections, high efficiency, fully regenerative current source and sink capability. Higher voltage and current possible by connecting units in series and parallel. The optional ripple generator (inject AC wave on top of DC output) is available for specialized testing. Full bridge models have 0-volt operation for applications like fuel cell testing.

Preprogrammed

Rather than program your own test profiles, you can select existing test programs developed by UNICO engineers. EV Battery cycler test programs that simulate real-world scenarios include:

  • Constant current discharge cycling
  • Constant and peak power testing
  • Variable-power testing
  • Federal Urban Driving Schedule (FUDS) and similar test regimes
  • Dynamic stress test (DST)
  • Partial discharge testing
  • Hill climb testing
  • Thermal performance testing
  • Fast charge testing
  • Life cycle testing

High Speed Link

Supports most industry standard communication protocol, making it versatile to work with any available automation system platform. A high-speed communications interface is optionally available to accept commands from existing customer controllers that are used to generate test profiles. Wired and fiber-optic options are available. Supported protocols include:

  • CANopen
  • CC-Link
  • ControlNet
  • DeviceNet
  • Ethernet
  • EtherCAT (async)
  • Interbus
  • LonWorks
  • Modbus Plus
  • Profibus DPV1
  • Profibus Maste
  • EtherCat (sync)

Safety and Protection

Built-in safety and control interlocks are hardwired, opto-isolated, and software configurable, so you can be confident pushing it to the edge.

Specifications

Unico Features

General Specifications

AC Input 480VAC, 3Ph, 50/60Hz (other voltages available on request)
Ambient Up to 40°C, max l000m above sea level, 95%RH non-condensing enclosure
Enclosure NEMA 1 (other options available upon request)Cabinet Paint
Cooling Air cooled (water cooled or airconditioned cabinets upon request)
Cabinet Paint RAL 7035 rough semi-gloss poly powder finish
Certification Compliance UL (other certifications available)
Control Modes Constant current, constant voltage, constant power
Control Local and remote e
Built in remote interface Analog as well as RS-422, RS-485, two ports (other interface and protocol, see options below)
Safety and control interlocks Hardwired, opto-isolated, software configurable
Measurement Accuracy 0.05% (system calibration required)
Voltage Ripple 0.10%
Current Ripple 0.10%
Unico Features

Options

Isolation transformer Various sizes as required
Insulation monitoring Available
Remote voltage sensing Available
Additional analog and digital input, output Technical discussion required
Cabinet paint finish Customer specific
Protection class NEMA 12
External communication interface CANopen, CC-Link, ControlNet, DeviceNet, Ethernet, EtherCAT (async), Interbus, LonWorks, Modbus Plus, Profibus DPV1, Profibus Master, EtherCat (sync)

Block Diagrams

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Brochures

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Resources

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Application used for Automotive

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Battery

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Inverter

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Inverter

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Battery

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Inverter

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Battery

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Inverter

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Battery

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Inverter

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Battery

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Fuel Cell

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Frequently
Asked Questions

A battery cycler measures the cell response over time and analyzes battery function by charge/discharge cycles. The parameters you can calculate using a battery cycler include capacity, self-discharge, and efficiency, among others. You can also use a battery cycler with capacitors and super-capacitors.
It is effortless to use a battery cycler system, and you can use it simply by following these steps:
  • Turn on the multimeter and then choose the mode named ‘DC voltage’.
  • Now, connect the multimeter test leading to the battery terminals.
  • Read the voltage shown on the gauge or multimeter display.
  • Load the battery with a satisfying result or repeat the process.
A battery cycler is important to test the available batteries and make the improvements. It is one of the integral components of battery laboratory testing equipment that many R&D experts use for battery cycling and DC testing.
The Unico battery cyclers combine the family of single and dual output DC power supplies with software specifically tailored for testing HEV battery packs, ultra and supercapacitor packs, fuel cells, power electronic converters, and other devices.