Battery Testing Challenges

Battery cell, module, and pack testing requires precise control of charge/discharge cycles, thermal conditions, and current flow to replicate real-world usage.

Verifying state of charge (SOC), state of health (SOH), and degradation over thousands of cycles presents a long-term data collection and management challenge.

Safety testing must simulate and analyze potential failure modes such as thermal runaway, short circuits, and overvoltage conditions.

Integration with battery management systems (BMS) adds complexity to testing communications, diagnostics, and system-level behavior.

High-voltage, high-current systems demand robust electrical safety protocols and hardware integration for test equipment and automation.

Battery Applications That Require Testing

Battery lifecycle testing evaluates performance degradation over time during repeated charge and discharge cycles.

Thermal management testing ensures battery packs maintain safe and efficient operating temperatures under various load conditions.

Abuse and safety testing assesses how battery systems react to overcharging, punctures, and thermal runaway events.

Fast-charging validation analyzes how cells handle high-speed charging without capacity loss or overheating.

Battery Management System (BMS) validation verifies communication protocols, fault detection, and balancing functionality.

Environmental and vibration testing confirms battery durability under temperature extremes, humidity, and mechanical stress.

A&D Services & Solutions for the Battery Industry

A&D provides battery-focused consulting services to evaluate your current test environment and recommend improvements in data acquisition, automation, and efficiency.

iTest.BTS streamlines automated control of charge/discharge equipment, environmental chambers, and cooling systems for battery test applications.

Battery HILS simulates battery behavior under vehicle operating conditions to support BMS development, hardware-in-the-loop testing, and controller validation.

LabWorX manages battery lab assets, test schedules, data storage, and reporting across complex battery development workflows.

ADX delivers portable, real-time simulation and control for on-site or mobile battery system testing environments.

A&D offers custom software development services to integrate with your existing battery cyclers, safety controllers, and data loggers.

Our project management team ensures battery test system builds are completed on time and meet performance and safety goals.

Installation and commissioning services ensure your battery testing hardware and software are fully integrated and verified for operation.

Training programs teach teams to operate A&D systems in battery test labs, including automation scripting, safety management, and data handling.

A&D support services provide helpdesk assistance, diagnostics, repairs, and access to spare parts and application updates for battery test operations.

Resident Engineers are available to work on-site to optimize and maintain your battery testing processes and technologies.