Battery Industry Solutions
Battery Industry Solution

Battery Manufacturing Process & Test Solutions

Explore professional measurement technologies and precision equipment across all stages of battery manufacturing, covering voltage, internal resistance, insulation, and current parameters.

Battery manufacturing process

Comprehensive testing and quality assurance across every stage of battery production.

Phase 01

Manufacturing Process Overview

From raw material processing to final cell assembly and packaging, strict testing parameters must be maintained to ensure safety, capacity, and longevity.

Phase 02

Production Line Test Stations

Integration of dedicated measurement instruments at critical manufacturing checkpoints to detect anomalies early and optimize overall production yield.

Phase 03

System Architecture & Setup

Demonstrating how multi-instrument hardware and specialized software solutions interconnect to build robust, highly accurate automated testing environments.

Voltage Measurement

  • Open circuit voltage : Refers to the voltage of the battery when it is not connected to an external circuit (load). The open circuit voltage has a certain relationship with the remaining energy of the battery, and the power display adopts this principle.
  • Operating voltage : Refers to the potential difference between the positive and negative terminals of a battery when it is in an active state with current flowing in the circuit, also known as the load voltage. In the operational state of battery discharge, when the current flows through the inside of the battery, it must overcome the resistance of the internal resistance, so the working voltage is always lower than the open circuit voltage.
  • Discharge cut-off voltage : Refers to the voltage reached after the battery is fully charged and fully discharged (if it continues to discharge, it is over-discharged, which will affect the life cycle and performance of the battery).
  • Charge limit voltage : When reaching the Charge limit voltage, the charging mode changes from constant current to constant voltage.

GDM-906x Dual Measurement Multimeter

6 1/2 Digit Display: 1,200,000 Counts

Capacity makes greatness
Relentless refinement
  • The code is 100% compatible with that of 34401A (System ID can also be changed to 34401A)
  • Best DC accuracy: ±(0.0035 + 0.0005), which is better than that of 34460A
  • The fastest measurement speed is 10 times faster than the industry benchmark (10 k reading/sec v.s. 1 k reading/sec)

Internal Resistance

  • DC internal resistance (DCIR) : According to the equivalent circuit of the battery, the DC measurement method is used, the capacitance is regarded as an open circuit, and the measured internal resistance is RΩ+ RCT.
  • AC internal resistance (ACIR) : According to the equivalent circuit of the battery, the AC measurement method is used, the capacitance is regarded as a short circuit, and the measured internal resistance is RΩ.
  • Structural contact resistance
  • EIS Electrochemical Impedance Spectroscopy : EIS can separate and quantify the cell resistance of the bulk (Rb), interface layer (RSEI), charge transfer reaction (Rct), and diffusion process (W) by a single experiment.

GBM-3000 Series Battery Meter

Dedicated Battery Tester (GBM-3300: 300V / GBM-3080: 80V)

All required functionalities in one
Mighty testing capability
  • Features voltage and internal resistance measurements
  • 3.5-inch LCD color screen: Intuitive settings and measurements
  • Best resolution: 0.1 µΩ and 10 µV

Contact Resistance and Battery Health Assessment

Contact Resistance & Thermal Coupling Effect

Accurate measurement of contact resistance at metal joints is critical. Pulse measurement technology is typically applied to eliminate errors caused by the thermal coupling effect of metal joints during testing.

Two-Pulse Test Method and EIS Electrochemical Impedance Spectroscopy

Battery Life Assessment

Source:IEEE TRANSACTIONS ON ENERGY CONVERSION, VOL. 23, NO. 2, JUNE 2008 An Improved Battery Characterization Method Using a Two-Pulse Load Test Martin Coleman, William Gerard Hurley, and Chin Kwan Lee

Recommended measurement methods:

  • Applying the discharge test function of the GMC-1000 MetaView IoT Wizard solution, three steps: discharge → idle → discharge to test the voltage and current, record the readings to find out △V2 and calculate it.
  • Applying the PEL-3000 series or the PEL-2000B series, the stand-alone unit function can also be used to calculate after obtaining the record file through the battery test mode.
  • Related EIS test functions are now available.

GOM-804&805 DC Milli-Ohm Meter

Pulse measurement to eliminate thermal coupling errors
  • High precision resistance measurement for contacts and joints
  • Pulse current output mode to prevent thermal electromotive force errors

Current Measurement for Battery Pack

Battery Pack Current Measurement Principle

High-current measurements in battery packs require precise current shunts to accurately capture dynamic charge and discharge currents, ensuring system efficiency, safety, and reliable data acquisition across testing cycles.

PCS-1000I Isolated Output High Precision Current Shunt Meter

Battery pack current measurement

High precision current shunting & measurement
  • Current range from 0.01 μA to 300 A
  • 6 1/2-digit voltage and current measurement resolution
  • USB & GPIB standard interfaces

Prodigit 7550A Precision Current Shunt

Reliable high-capacity current testing solution
  • Current range: 1 μA to 250 A
  • Performing remote testing with an external DVM
  • Front panel input design for operational convenience

Prodigit 1000A Precision Current Shunt

Heavy-duty high-current shunting system
  • Current range: 1 μA to 1000 A
  • Interfaces: USB, RS-232, GPIB, LAN (optional)
  • Front panel input design for easy test configuration
(Swipe left or right to view the full table.)
Brand/Model Current range Interface Input panel Other functions
PCS-1000I 0.01 μA to 300 A USB & GPIB Front panel 6 1/2-digit voltage and current measurement resolution
7550A 1 μA to 250 A Performing remote testing with an external DVM Front panel -
1000A 1 μA to 1000 A USB, RS-232, GPIB LAN (optional) Front panel -
1000A-R 1 μA to 1000 A USB, RS-232, GPIB LAN (optional) Front panel -

Insulation Material Analysis

The Determination of Insulation Breakdown

The current flowing through the insulation to be tested can already generate a corresponding current (steep rise out of control) with the increase of the test voltage, that is, the insulation to be tested can no longer effectively limit the increase of the current under the test electric field strength. Therefore, only setting the upper limit of the leakage current will cause misjudgment. Insulation material analyzer must have the ability to display the VI curve in order to correctly determine the insulation breakdown.

GPT-12000 Electrical Safety Analyzer

200VA AC Test Capacity

Advanced safety testing with VI curve analysis
  • Comprehensive electrical safety and insulation breakdown analysis
  • Equipped with real-time VI waveform display capabilities

Feedback & Inquiries

If you have any comments or questions regarding our battery testing solutions, please feel free to reach out to our team.

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Battery Manufacturing Overview
Production Line Test Stations
System Architecture & Application
Voltage Characteristics Chart
Internal Resistance Diagram
Two-Pulse Test Method
Insulation Breakdown Analysis