lithium ion battery formation

Advanced Multi-Channel Battery Testing and Formation System for Square Aluminum-Shell Lithium-Ion Cells

This cutting-edge battery testing and formation solution is engineered specifically for square aluminum-shell lithium-ion batteries, delivering precision performance across charge-discharge cycles, vacuum-assisted formation, and intelligent grading. Designed for high-volume manufacturing environments, this integrated system combines bidirectional DC/DC power conversion, real-time data logging, and a robust multi-channel protection architecture to ensure safety, efficiency, and scalability in modern battery production.

At its core, the equipment features 128 independent constant current/voltage sources per channel, enabling parallel processing of multiple cells with response times under 50 milliseconds. It supports up to 256 programmable test cycles using 32 customizable steps—ideal for adapting to various cell sizes ranging from 80mm to 300mm in length. The built-in negative pressure vacuum system allows precise control between -100 kPa and 0 kPa during formation, reducing electrolyte loss and improving consistency in cell activation. With automatic self-calibration, TCP/IP communication, and one-second data sampling intervals, it ensures seamless integration into industrial automation frameworks such as MES or SCADA systems.

The system’s advanced capabilities include an embedded smart grading algorithm that evaluates over ten key parameters—including capacity, internal resistance, voltage stability, and discharge profiles—to sort batteries with an accuracy of ±0.5‰. This level of granularity enhances quality assurance while maintaining traceability throughout the production lifecycle. Furthermore, the hardware utilizes high-resolution AD/DA converters (1mA / 0.1mV resolution) for accurate measurement, supporting techniques like delta-V termination and capacity decay analysis to optimize battery performance modeling and lifetime prediction.

Key technical advantages include a dual-function electric clamping tray for secure terminal contact, low heat generation due to >80% energy efficiency, and 12 independent protection mechanisms covering overvoltage, undervoltage, reverse polarity, and overcurrent scenarios. These features collectively reduce downtime, prevent defects, and support continuous operation for up to 12 hours without interruption—ensuring minimal disruption in mass production settings.

Designed for diverse applications, this system excels in large-scale battery manufacturing, where rapid throughput and consistent quality are critical. Its compatibility with automated assembly lines makes it ideal for factories producing thousands of units daily. In quality inspection workflows, it enables real-time monitoring of more than 20 KPIs, allowing immediate detection of anomalies before they reach downstream processes. For research and development teams, the flexible programming interface supports detailed charge/discharge curve analysis, cycle life testing, and custom protocol design—accelerating innovation in next-generation battery technologies.

Manufacturers worldwide rely on this platform not only for compliance with international standards but also for achieving higher yield rates and operational efficiency. Whether optimizing existing production lines or launching new battery formats, this equipment provides the flexibility, precision, and reliability required to meet evolving market demands.

Users report significant improvements in process consistency, reduced manual intervention, and enhanced data visibility across entire battery batches. Many highlight how the system’s ability to handle variable chemistries and maintain grading accuracy—even under fluctuating raw material conditions—makes it indispensable in both mature and emerging battery markets.

Frequently asked questions often center around setup complexity, but users note that intuitive software interfaces and guided calibration tools simplify deployment. Another common inquiry involves compatibility with different battery types; the system’s modular design allows adaptation to various form factors beyond square aluminum-shell cells. Additionally, concerns about maintenance are addressed by the durable construction and self-diagnostic functions that minimize service requirements while maximizing uptime.