Tech Briefs Magazine - December 2023 - BET-18

Engineers might be tasked with integrating systems
they are not trained on. (Image: EA Elektro-Automatik).
Mistakes to Avoid
When Integrating a
Battery Test System
Test systems should be designed in a way to recover the energy locally and utilize the
inherent benefit of electric vehicles to share charge and discharge energy on a testbed level.
I
18
t's not easy to configure a battery cycle test system for EV
batteries and similar high-power batteries. Many components,
such as contactors, power supplies, cyclers, data
acquisition and sensors, need to be made into a system
using software and challenging connections. Getting it
wrong could increase costs, disrupt production, or possibly
injure or kill workers. This article covers the mistakes that engineers
sometimes make when integrating a battery test system.
Manufacturers can build the system themselves, hire an integrator,
or buy a turnkey system. Each of these has pros and cons.
If the manufacturer has experts on staff, then integrating the
system internally saves money. However, it will consume time in
research and troubleshooting and run the risk of mistakes. Even
experienced engineers don't know how the components will work
together until they plug them in. And many manufacturers don't
even have experienced engineers on staff. In addition, many executives
worry about safety issues if the company is integrating a system
themselves. Also, with new equipment and innovations comes
the risk of inexperience with the latest integration knowledge.
Professional integrators are staffed with experts, but they are
expensive. An integrator will charge for each change. Pity the
manager who gets invoiced each time a programmer flies in or
remotes in to change a single line of code.
Turnkey systems may require a tweak or two to fit proprietary
equipment or tests, but the engineer will have confidence that
the components play well together. While running the risk of
being locked into one supplier, integrating with internal resources
or an integrator allows the manufacturer to get the
desired components and system.
Some turnkey test systems suppliers are willing to customize
things like the communications bus and spread the integration
costs across multiple orders. The user gets the configuration
they want for a reasonable cost.
Whatever the approach, engineers should avoid common mistakes.
Poor Component Selection
A common mistake is selecting unsuitable components for
the test system, or ones that won't perform reliably. A good
example is a contactor. Sometimes, engineers choose inexpensive
contactors to save money. The risk here is that operators
may have to replace the contactors every few months, disrupting
testing.
Battery & Electrification Technology, December 2023

Tech Briefs Magazine - December 2023

Table of Contents for the Digital Edition of Tech Briefs Magazine - December 2023

Tech Briefs Magazine - December 2023 - Intro
Tech Briefs Magazine - December 2023 - Sponsor
Tech Briefs Magazine - December 2023 - Cov1
Tech Briefs Magazine - December 2023 - Cov2
Tech Briefs Magazine - December 2023 - 1
Tech Briefs Magazine - December 2023 - 2
Tech Briefs Magazine - December 2023 - 3
Tech Briefs Magazine - December 2023 - 4
Tech Briefs Magazine - December 2023 - 5
Tech Briefs Magazine - December 2023 - 6
Tech Briefs Magazine - December 2023 - 7
Tech Briefs Magazine - December 2023 - 8
Tech Briefs Magazine - December 2023 - 9
Tech Briefs Magazine - December 2023 - 10
Tech Briefs Magazine - December 2023 - 11
Tech Briefs Magazine - December 2023 - 12
Tech Briefs Magazine - December 2023 - 13
Tech Briefs Magazine - December 2023 - 14
Tech Briefs Magazine - December 2023 - 15
Tech Briefs Magazine - December 2023 - 16
Tech Briefs Magazine - December 2023 - 17
Tech Briefs Magazine - December 2023 - 18
Tech Briefs Magazine - December 2023 - 19
Tech Briefs Magazine - December 2023 - 20
Tech Briefs Magazine - December 2023 - 21
Tech Briefs Magazine - December 2023 - 22
Tech Briefs Magazine - December 2023 - 23
Tech Briefs Magazine - December 2023 - 24
Tech Briefs Magazine - December 2023 - 25
Tech Briefs Magazine - December 2023 - 26
Tech Briefs Magazine - December 2023 - 27
Tech Briefs Magazine - December 2023 - 28
Tech Briefs Magazine - December 2023 - 29
Tech Briefs Magazine - December 2023 - 30
Tech Briefs Magazine - December 2023 - 31
Tech Briefs Magazine - December 2023 - 32
Tech Briefs Magazine - December 2023 - 33
Tech Briefs Magazine - December 2023 - 34
Tech Briefs Magazine - December 2023 - 35
Tech Briefs Magazine - December 2023 - 36
Tech Briefs Magazine - December 2023 - 37
Tech Briefs Magazine - December 2023 - 38
Tech Briefs Magazine - December 2023 - 39
Tech Briefs Magazine - December 2023 - 40
Tech Briefs Magazine - December 2023 - 41
Tech Briefs Magazine - December 2023 - Cov4
Tech Briefs Magazine - December 2023 - MD-Cov1
Tech Briefs Magazine - December 2023 - MD-Cov2
Tech Briefs Magazine - December 2023 - MD-1
Tech Briefs Magazine - December 2023 - MD-2
Tech Briefs Magazine - December 2023 - MD-3
Tech Briefs Magazine - December 2023 - MD-4
Tech Briefs Magazine - December 2023 - MD-5
Tech Briefs Magazine - December 2023 - MD-6
Tech Briefs Magazine - December 2023 - MD-7
Tech Briefs Magazine - December 2023 - MD-8
Tech Briefs Magazine - December 2023 - MD-9
Tech Briefs Magazine - December 2023 - MD-10
Tech Briefs Magazine - December 2023 - MD-11
Tech Briefs Magazine - December 2023 - MD-12
Tech Briefs Magazine - December 2023 - MD-13
Tech Briefs Magazine - December 2023 - MD-14
Tech Briefs Magazine - December 2023 - MD-15
Tech Briefs Magazine - December 2023 - MD-16
Tech Briefs Magazine - December 2023 - MD-17
Tech Briefs Magazine - December 2023 - MD-18
Tech Briefs Magazine - December 2023 - MD-19
Tech Briefs Magazine - December 2023 - MD-20
Tech Briefs Magazine - December 2023 - MD-21
Tech Briefs Magazine - December 2023 - MD-Cov4
Tech Briefs Magazine - December 2023 - BET-CoverFlap
Tech Briefs Magazine - December 2023 - BET-Cov1B
Tech Briefs Magazine - December 2023 - BET-Cov1
Tech Briefs Magazine - December 2023 - BET-Cov2
Tech Briefs Magazine - December 2023 - BET-1
Tech Briefs Magazine - December 2023 - BET-2
Tech Briefs Magazine - December 2023 - BET-3
Tech Briefs Magazine - December 2023 - BET-4
Tech Briefs Magazine - December 2023 - BET-5
Tech Briefs Magazine - December 2023 - BET-6
Tech Briefs Magazine - December 2023 - BET-7
Tech Briefs Magazine - December 2023 - BET-8
Tech Briefs Magazine - December 2023 - BET-9
Tech Briefs Magazine - December 2023 - BET-10
Tech Briefs Magazine - December 2023 - BET-11
Tech Briefs Magazine - December 2023 - BET-12
Tech Briefs Magazine - December 2023 - BET-13
Tech Briefs Magazine - December 2023 - BET-14
Tech Briefs Magazine - December 2023 - BET-15
Tech Briefs Magazine - December 2023 - BET-16
Tech Briefs Magazine - December 2023 - BET-17
Tech Briefs Magazine - December 2023 - BET-18
Tech Briefs Magazine - December 2023 - BET-19
Tech Briefs Magazine - December 2023 - BET-20
Tech Briefs Magazine - December 2023 - BET-21
Tech Briefs Magazine - December 2023 - BET-22
Tech Briefs Magazine - December 2023 - BET-23
Tech Briefs Magazine - December 2023 - BET-24
Tech Briefs Magazine - December 2023 - BET-25
Tech Briefs Magazine - December 2023 - BET-26
Tech Briefs Magazine - December 2023 - BET-27
Tech Briefs Magazine - December 2023 - BET-28
Tech Briefs Magazine - December 2023 - BET-29
Tech Briefs Magazine - December 2023 - BET-30
Tech Briefs Magazine - December 2023 - BET-31
Tech Briefs Magazine - December 2023 - BET-32
Tech Briefs Magazine - December 2023 - BET-33
Tech Briefs Magazine - December 2023 - BET-34
Tech Briefs Magazine - December 2023 - BET-35
Tech Briefs Magazine - December 2023 - BET-36
Tech Briefs Magazine - December 2023 - BET-37
Tech Briefs Magazine - December 2023 - BET-38
Tech Briefs Magazine - December 2023 - BET-39
Tech Briefs Magazine - December 2023 - BET-40
Tech Briefs Magazine - December 2023 - BET-41
Tech Briefs Magazine - December 2023 - BET-42
Tech Briefs Magazine - December 2023 - BET-Cov3
Tech Briefs Magazine - December 2023 - BET-Cov4
https://www.nxtbook.com/smg/techbriefs/25TB02
https://www.nxtbook.com/smg/techbriefs/25TB01
https://www.nxtbook.com/smg/techbriefs/24TB12
https://www.nxtbook.com/smg/techbriefs/24TB11
https://www.nxtbook.com/smg/techbriefs/24TB10
https://www.nxtbook.com/smg/techbriefs/24TB09B
https://www.nxtbook.com/smg/techbriefs/24TB09
https://www.nxtbook.com/smg/techbriefs/24TB08
https://www.nxtbook.com/smg/techbriefs/24TB07
https://www.nxtbook.com/smg/techbriefs/24TB06
https://www.nxtbook.com/smg/techbriefs/24TB05B
https://www.nxtbook.com/smg/techbriefs/24TB05
https://www.nxtbook.com/smg/techbriefs/24TB04
https://www.nxtbook.com/smg/techbriefs/24TB03
https://www.nxtbook.com/smg/techbriefs/24TB02
https://www.nxtbook.com/smg/techbriefs/24TB01
https://www.nxtbook.com/smg/techbriefs/23TB12
https://www.nxtbook.com/smg/techbriefs/23TB11
https://www.nxtbook.com/smg/techbriefs/23TB10
https://www.nxtbook.com/smg/techbriefs/23TB09
https://www.nxtbook.com/smg/techbriefs/23TB08
https://www.nxtbook.com/smg/techbriefs/23TB07
https://www.nxtbook.com/smg/techbriefs/23TB06
https://www.nxtbook.com/smg/techbriefs/23TB05
https://www.nxtbook.com/smg/techbriefs/23TB04
https://www.nxtbook.com/smg/techbriefs/23TB03
https://www.nxtbook.com/smg/techbriefs/23TB02
https://www.nxtbook.com/smg/techbriefs/23TB01
https://www.nxtbook.com/smg/Testing/22TB12
https://www.nxtbook.com/smg/techbriefs/22TB12
https://www.nxtbook.com/smg/techbriefs/22TB11
https://www.nxtbook.com/smg/techbriefs/22TB10
https://www.nxtbook.com/smg/techbriefs/22TB09
https://www.nxtbook.com/smg/techbriefs/22TB08
https://www.nxtbook.com/smg/techbriefs/22TB07
https://www.nxtbook.com/smg/techbriefs/22TB06
https://www.nxtbook.com/smg/techbriefs/22TB05-P
https://www.nxtbook.com/smg/techbriefs/22TB05-D
https://www.nxtbook.com/smg/techbriefs/22TB04
https://www.nxtbook.com/smg/techbriefs/22TB03
https://www.nxtbook.com/smg/techbriefs/22TB02
https://www.nxtbook.com/smg/techbriefs/22TB01
https://www.nxtbook.com/smg/techbriefs/21TB12
https://www.nxtbook.com/smg/techbriefs/21TB11
https://www.nxtbook.com/smg/techbriefs/21TB10
https://www.nxtbook.com/smg/techbriefs/21TB09
https://www.nxtbook.com/smg/techbriefs/21TB08
https://www.nxtbook.com/smg/techbriefs/21TB07
https://www.nxtbook.com/smg/techbriefs/21TB06
https://www.nxtbook.com/smg/techbriefs/21TB05
https://www.nxtbook.com/smg/techbriefs/21TB04
https://www.nxtbook.com/smg/techbriefs/21BT03
https://www.nxtbook.com/smg/techbriefs/21TB02
https://www.nxtbookmedia.com