USA Office Address
India Office AddressE-Mobility Battery Solutions
At ITE, we offer comprehensive solutions for the development, assembly, and testing of e-mobility batteries. Our services cover the entire battery lifecycle, ensuring high-quality, reliable, and efficient battery systems for electric vehicles. We specialize in the following key areas:
Cell Grading and Testing
Cell Grading and Testing
We conduct meticulous cell grading and testing to categorize battery cells based on their performance characteristics, such as capacity, voltage, and internal resistance. This ensures that only high-quality cells are used, contributing to the overall reliability of battery packs. However, this thorough testing can add time to the production process, potentially impacting overall timelines.
- Deep understanding of lithium-ion battery chemistry and failure modes, ensuring enhanced reliability and safety.
- Skilled in identifying and mitigating potential manufacturing defects that impact battery performance and lifespan.
- Knowledgeable in selecting appropriate battery grades (A, B, or C) based on testing and intended applications, ensuring optimal battery pack performance.
- Comprehensive testing for cell grading, including capacity, internal resistance, and self-discharge rates.
- Quality sorting of cells (A, B, or C grades) to ensure consistent performance across battery packs.
- Advanced inspection methods to identify manufacturing defects such as impurities, burrs, or delamination that affect reliability and safety.
- Voltage/Capacity Testing : For consistent cell grouping and precise capacity determination.
- Self-Discharge Testing : Extended tests for long-term reliability.
- Internal Resistance : AC/DC Internal Resistance (IR), Electrochemical Impedance Spectroscopy (EIS).
- HiPot & Insulation : HiPot (DW, Insulation Resistance) and Isolation Voltage.
Module Assembly and Testing
We provide modular assembly solutions that integrate cutting-edge technology for flexible and standardized battery module production. Our module assembly process supports various cell formats and includes rigorous testing to guarantee safety, performance, and durability.
- ITE offers comprehensive battery testing for cells, modules, and packs across multiple formats (prismatic, pouch, cylindrical).
- Specialized in performance, endurance, environmental, and mechanical testing to meet international standards such as UL, IEC, UN, and ISO.
- Expertise in module assembly with standardized, flexible, and highly automated solutions for super modules and battery packs.
- Proficiency in battery module production testing and validation.
- Flexible, standardized solutions for all cell formats in module assembly.
- Automated processes using guided vehicles and conveyor belts for efficient battery pack assembly.
- High automation for complex processes, ensuring fast cycle times and streamlined workflows.
- Testing for diverse conditions, including environmental, corrosion, and fire resistance, along with endurance and mechanical integrity.
- Performance Testing: Durability, capacity, efficiency, and swelling force.
- Environmental Testing: Vibration, shock, corrosion, vacuum chamber, and UN 38.3 transport tests.
- Abuse & Mechanical Testing: Crush, thermal propagation, overcharge, deep discharge, short circuit.
- EoL Testing: Isolation, HPPC, leakage, communication for production validation.
- Module Testing: Weld/Busbar Resistance, Communication (CAN/ISOSPI/ISOUART), OCV (Module/Cells), Temperature (Module/Cells), Current Calibration, DCIR (Module/Cells), Charge/Discharge, SOC/SOH Estimation, HiPot (DW, Insulation Resistance), Leak Test.
Module Assembly and Testing
Battery Pack Assembly and Testing
Battery Pack Assembly and Testing
Our battery pack assembly services focus on high-efficiency solutions, incorporating automated guided vehicles (AGVs) and conveyor systems to streamline production. We ensure precise integration of modules and other components into complete battery packs, designed to meet the highest standards of reliability.
- ITE specializes in comprehensive battery pack assembly testing, focusing on performance, safety, and quality to ensure reliable operation in EV and PHEV applications.
- Expert in Battery Energy Management (BEM) and Battery Management System (BMS) testing, which ensures accuracy in state-of-charge estimation, voltage/current monitoring, and temperature management.
- Proficiency in simulating real-world conditions to verify the durability and safety of battery packs under various stress scenarios.
- Thorough testing of communication protocols including CAN, Flex ray, and LIN for efficient BMS operations.
- Advanced testing for temperature and voltage monitoring at the pack, module, and cell levels to ensure stability and safety.
- Rigorous charge/discharge, pre-charge, and drive cycle tests that replicate real-world usage.
- High-level integration of HV/LV systems, ensuring connectivity and isolation across terminals.
- Open Circuit Voltage (OCV) : temperature, and DC Internal Resistance (DCIR) for packs, modules, and individual cells.
- SOC/SOH : estimation for monitoring battery health and efficiency.
- Leak tests : insulation resistance, and ground isolation tests for enhanced safety.
- HiPot : HV/LV terminal isolation resistance, and shield impedance testing for ensuring electrical safety.
- Vehicle environment simulations : to validate pack performance under operational conditions.
BMS Testing
Battery Management System (BMS) testing ensures the safe operation and efficiency of battery packs by evaluating cell balancing, thermal management, and fault detection. These tests provide vital safety assurances but can require complex test protocols that may be time-consuming for highly integrated systems.
- ITE excels in seamlessly integrating and testing Battery Management Systems (BMS) for optimal battery performance, safety, and efficiency.
- Expertise in validating complete BMS systems through software simulation, hardware-in-the-loop (HiL) testing, and real-world scenario emulation.
- Skilled in ensuring proper communication between Battery Management Controllers (BMC) and Cell Management Controllers (CMC), critical for efficient battery control and monitoring.
- Simulation and control of individual battery cells with programmable models such as Li-Ion, enabling precise cell monitoring.
- Real-time monitoring of battery parameters like voltage, charge/discharge current, and State of Charge (SOC).
- Scalable testing solutions adaptable to the number of cells in the system.
- Advanced communication verification for CAN, LIN, SPI, and UART buses with detailed frame analysis, bus timing, and error detection.
- Spectrum analysis to visualize anomalies, EMI effects, and events in both time and frequency domains.
- BMS Data Analysis : CAN communication and data transfer testing.
- Voltage and Temperature : Cell and pack voltage/temperature monitoring.
- Contactor Test : Contactor characterization and diagnostic fault mode tests.
- Connection Test : Precharging and air leak tests for coolant connections.
- Performance Test : Performance testing including capacity, charge/discharge/rest cycles.
- Voltage Test : Voltage stability and internal isolation measurement.
BMS Testing
