Automatic and Versatile Test Bench for Data Collection on Battery Cells
Abstract
:1. Introduction
2. Basics of Lithium-Ion Battery Degradation and Operation
3. Proposed Framework for Testing Lithium-Ion Batteries
- Personal Computer: manages and controls the test bench.
- Power Supply: Sorensen DLM20-30, AMETEK, Inc., Berwyn, PA, USA (600 W), providing the necessary testing voltage. The system can handle the voltage and current required by the single battery pack (up to a maximum of 20 V and 30 A supplied by this electronic equipment). This is a major limitation of our system. Higher voltage or current testing values require another power supply.
- Router: D-Link D-300, D-Link Corporation, Taiwan, facilitating communication between devices.
- Electronic load: B&K Precision 8614, B&K Precision Corporation, Yorba Linda, CA, USA, designed to emulate battery charge and discharge conditions by dynamically adjusting voltage and current parameters. This allows accurate characterization of battery performance under various load scenarios.
- I/O Device: National Instruments USB-6281, Emerson Electric Co., St. Louis, MO, USA, serving as the test bench’s monitoring platform. It enables battery temperature measurement and allows system expansion by integrating additional relays and external monitoring devices.
- Thermocouple: K type, ensuring accurate thermal monitoring by measuring battery temperature during analysis.
- It uses a LabVIEW environment to control and monitor the test bench. The developed software package allows the programming of charge and discharge cycles, real-time tracking of battery parameters, and data storage in plain text format for further analysis.
- Python (version 3.12.7) was used to develop a post-processing data tool and generate graphical representation of the results obtained.
4. Experimental Validation
- The initial configurations are established, where the file names for the first charge and discharge cycles are defined as “Charge1.txt” and “Discharge1.txt”. The charging voltage is set at 3.65 V, the maximum charging and discharging current is set at 6 A, the minimum discharge voltage is set at 2.5 V, and a data sampling period of 1 s is established.
- The battery charging process begins with a CC-CV profile. Initially, charging begins with a CC at a rate of 1 C (6 A) until the battery reaches a voltage of 3.65 V (maximum charging voltage). Subsequently, a CV phase is applied at 3.65 V until the current decreases to a threshold of 0.5 A or less, at which point the software automatically terminates the charging process Figure 9a. During this process, the charging data is recorded in a charging text file. The data include the charging current measured by the power supply, the voltage provided by the power supply, the temperature measured by the thermocouple, and the time recorded in LabVIEW. These data are continuously logged and periodically exported.
- After a rest period of 20 min, the discharging process is initiated using a CC of 6 A, until the battery reaches a voltage of 2.5 V (minimum voltage). At this point, the discharging process is automatically stopped, see Figure 9b. During this process, discharge data are recorded in a discharge text file. These data include the discharging current measured by the programmable load, the voltage provided by the power supply, the temperature measured by the thermocouple, and the time recorded in LabVIEW. It is noteworthy that data during the resting periods are also stored in the discharging file, ensuring that all relevant information, including the intervals between charging and discharging cycles, is captured for further analysis Figure 9b.
- Subsequently, a 20-min rest period begins. Once this period ends, new text files are generated for the next charging and discharging processes, and the cycle restarts from Step 1.
- Charging procedure: a CC-CV profile is followed. Initially, a constant current of 1 C (6 A) is applied until the battery voltage reaches 3.65 V. Then, the process switches to constant voltage mode at 3.65 V, maintaining this level until the current decreases to 0.5 A.
- Resting period: the battery is left to rest for 20 min once the charge is complete, allowing the voltage to relax.
- Discharging process: the discharge process begins after the resting period, applying a constant current of 1 A. During discharge, the process is paused every 30 min for 10 min to record multiple open-circuit voltage points. The discharge continues until the battery voltage drops to 2.5 V, which is the discharge cut-off voltage and causes the cycle to stop completely.
5. Conclusions
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Category | Representative Methods | Pros | Cons |
---|---|---|---|
Direct and empirical | Coulomb counting, internal resistance, electrochemical impedance spectroscopy | Simple implementation; Physically interpretable; High accuracy under lab conditions | Requires controlled environments; Poor performance for online estimation; Sensitive to noise and aging |
Physics-based models | Electrochemical model, equivalent circuit model | Mechanistic insight; Captures degradation mechanisms; Enables predictive modeling | High computational cost; Difficult parameter identification |
Stochastic filters | Kalman filter, particle filter | Real-time estimation; Handles noisy/incomplete data; Adaptable to system changes | Model-dependent; Computationally intensive; Sensitive to initialization |
Curve Analysis Techniques | Incremental capacity analysis, differential voltage analysis, peak tracking | Non-invasive; Detects specific degradation modes; Useful for cell diagnostics | Requires high-resolution data; Sensitive to noise; Not suitable for real-time use |
Machine Learning | Support vector machines, random forest, artificial neural networks, gradient boosting machines | Learns complex nonlinear patterns; Suitable for real-time applications; Can integrate into BMS | Needs large, labeled datasets; Risk of overfitting; Often lacks physical interpretability |
Hybrid & Physics-Guided | Physics-informed neural networks, Kalman filters + Machine learning, multi-model ensemble learning, transfer learning/domain adaptation | Combines data and physics; High accuracy and generalization; Adaptive and robust | Complex to design and tune; Synchronization of models is challenging; Often still in research phase |
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Marsal, E.; Martínez, N.; Pérez Vega-Leal, A.; Barrero, F.; Hamdan, M.; Satué, M.G. Automatic and Versatile Test Bench for Data Collection on Battery Cells. Energies 2025, 18, 2304. https://doi.org/10.3390/en18092304
Marsal E, Martínez N, Pérez Vega-Leal A, Barrero F, Hamdan M, Satué MG. Automatic and Versatile Test Bench for Data Collection on Battery Cells. Energies. 2025; 18(9):2304. https://doi.org/10.3390/en18092304
Chicago/Turabian StyleMarsal, Esteban, Nicolás Martínez, Alfredo Pérez Vega-Leal, Federico Barrero, Mohamad Hamdan, and Manuel G. Satué. 2025. "Automatic and Versatile Test Bench for Data Collection on Battery Cells" Energies 18, no. 9: 2304. https://doi.org/10.3390/en18092304
APA StyleMarsal, E., Martínez, N., Pérez Vega-Leal, A., Barrero, F., Hamdan, M., & Satué, M. G. (2025). Automatic and Versatile Test Bench for Data Collection on Battery Cells. Energies, 18(9), 2304. https://doi.org/10.3390/en18092304