Case Study: High-Throughput Battery Cell Aging Automation Using ATE Integration

This battery cell aging automation case study details how a leading US system integrator leveraged TPS power hardware to solve a critical production bottleneck for their automotive supplier client. This is a prime example of an ATE integration case study where the right power component was the key to success.

The Challenge: Bottlenecks in Scaling Automated Battery Testing

Battery cell aging is a mandatory but time-consuming part of the manufacturing process. The client's customer needed to scale its production line, which meant moving from R&D-scale manual testing to a fully automated, high-throughput battery testing process.

They faced several challenges:

• Integration: The ATE host computer needed to control hundreds of power channels, read back data, and simultaneously control environmental temperature chambers.
• Efficiency: Traditional test methods use resistive loads to discharge batteries, wasting 100% of the discharge energy as heat and increasing HVAC costs.
• Speed & Accuracy: The system required fast current response times (milliseconds) for advanced tests and high accuracy for data logging[cite: 154, 152].

The Solution: A PLC-Controlled Bidirectional Power System

The client selected TPS programmable bidirectional power supplies as the core of their power hardware. The solution was built on two key capabilities: system architecture and component-level performance.

System Architecture: Integrating Power, PLC, and Temp Chamber Control

Instead of a fragmented system, the integrator used a central PLC as the "brain" to manage the test sequence. The TPS power supplies were perfectly suited for this PLC-controlled power supply system.

Via the built-in CAN bus protocol, the PLC could:

• Send precise charge/discharge commands to hundreds of channels.
• Execute complex test functions like matrix following[cite: 156].
• Natively control the temperature chamber, pausing or stopping tests if thermal limits were breached[cite: 155].

Achieving Fast Response & High Accuracy

The TPS hardware provided the performance needed for complex test profiles. With a 3ms current response time and 0.03% FSR accuracy[cite: 154, 152], the ATE system could execute rapid simulation pulses and log highly accurate data, giving the end client full confidence in their cell quality.

The Results: 40% Increase in Throughput and Measurable Energy Savings

The fully integrated system was a definitive success. By replacing the old, non-regenerative power supplies with a fully automated, bidirectional system, the client achieved clear, measurable results.

Key Takeaways for Your ATE Integration Project

This battery cell aging automation case study provides a clear blueprint for success in high-throughput testing. The key takeaways are:

1. Choose Power Supplies Built for Integration: Success depends on hardware that speaks standard protocols (like CAN or Modbus) and has proven PLC compatibility.
2. Embrace Regeneration: Bidirectional, regenerative power supplies are no longer a luxury. They are a core requirement for reducing energy costs and simplifying thermal management in production-scale test systems.
3. Unify Your Controls: A single, centralized ATE host or PLC that can control power, temperature, and safety protocols is the key to achieving true, reliable automation[cite: 155].

Design Your Automated Test Solution with TPS

Whether you are a system integrator building an ATE solution or an engineer looking to automate your in-house testing, our team can help. We provide the high-performance power components that make complex automation possible.