The Competition of the EVs Is On! Apart from the Fancy Outlook, What Need to Be Considered?

It not a surprise at this year’s Shanghai Auto Show, many companies have debuted their electric vehicle realm. In meeting such promising demand, the EV battery market is expected to experience significant growth in the coming years. According to Report Linker's latest analysis, the EV battery market is projected to have a compound annual growth rate (CAGR) of 19.57% from 2022 to 2027. As a result, battery manufacturers are focusing on increasing their EV battery production capacity and the reliability to maintain the car manufacturer competitive advantage. What establishes a reliable battery?

Optimizing Electrical Safety Testing Increased Battery Production Reliability

To maintain production reliability, EV battery manufacturers should focus on optimizing the production line's electrical safety testing process. Before batteries can be used in EVs, they need to pass the hipot test, which applies twice the rated voltage (usually 600 Vdc to 1200Vdc) for 60 seconds on multiple points, such as between the positive terminal and chassis, and negative terminal and chassis, to detect any battery breakdown. In addition, the ground bond/continuity test applies 25A DC current to check whether the ground resistance less than 0.1 Ω, helping prevent potential safety incidents. If these tests can be simplified to a one-click test, eliminating the need for operators to repeatedly switch testing leads and reducing the likelihood of errors, which can increase testing efficiency and reliability.

Reliable and Efficient EV Battery Testing Solution

Therefore, to optimize production line testing, choosing the appropriate testing solution is key. As mentioned above, EV battery manufacturers aim to enhance the reliability of their products by improving the efficiency of performing Hipot and ground bond/continuity tests. To accomplish this, they can use the HypotULTRA® Series Electrical Safety Tester model 7850 with a built-in scanner module, the HYAMP® Ground Bond Tester, and pair them with our WithStand® software.

The HypotULTRA® Series Electrical Safety Tester is an all-in-one solution that offers several benefits, including improved test simplicity, safety, and reliability. It provides up to 5kVac/6kVdc Hipot voltage, meeting the necessary testing requirements. The device is user-friendly, with an intuitive touch panel and a built-in scanner that saves time by eliminating the need to switch testing leads. Additionally, the device offers SmartGFI® and fast discharge features, which prioritize operator safety. The barcode scanner allows for direct data capture, preventing any result mix-ups. The HYAMP® 3240 Ground Bond Tester brings together AC and DC ground bond testing capability in a compact size design. It offers a maximum 40A current measurement capability and high-accuracy performance.

Both devices can be controlled using the WithStand software, which allows operators to easily set up and run tests, record data, and store it in the cloud for easy access and analysis. By using the HypotULTRA® and HYAMP® together with WithStand® software, EV battery manufacturers can efficiently and reliably ensure the safety and quality of their products.

If you need hands-on training on EV testing, Ikonix also offer application consultants to help you and your team understand the electrical safety tests and improve testing efficiency and productivity.