[SpeedRacer93]

Does anyone have a DIY design for an automated battery cell tester?

As my other post points out I am looking to build a battery pack for a race car with a large volt and amp draw. It has gotten down to the fact that we need to test cells to confirm advertised specs or discover unknown specs.

Thinking something using an arduino to control the load and log the data. Then I can use a PC to analyze the data from those logs.

The data will then be used to build up the complete race pack.

Specs for the test rig:

0-15 Volt (most cells are 3.2 to 4.2 Volts)
Up to 1500 AMP
Up to 8000 Watts

Max Load tests will run up to 2 minutes.
Lower 1C tests will be run upto an hour.

Would like the cells and test equipment to be water cooled by aluminium plates.

I would like to log: Time, Cell volts, Output AMPs, Cell Temp, Water Inlet temp, Water exit temp (anything else people can think of)

May want monitor more than one cell in a parallel or serial configuration.

Here are a couple that I have been looking at to use as a starting point and maybe scale up.

https://www.instructables.com/id/Arduino-Programmable-Constant-Current-Power-Resist/

https://www.youtube.com/watch?v=acAuW0IVXKw

I know that West Mountain has a tester for up to 2000W.
http://www.westmountainradio.com/product_info.php?products_id=sys2000_watt

Also I know some DC electronic loads like from BK Precision and they can do battery tests also they get up to $10,000.

 

[SpeedRacer93]

Built into iCharger Duo units innit?

The iCharge Duo can only do 40 AMP with external sink. I am looking doing 0-15 V, 1500 AMP and up to 8000 watts.

Looking at driving parallel IGBTs dumping to a heating elements in a water tank with cold water refresh once water gets up to temp. The IGBTs will be on a cooling plate also.

(Honey, I am just heating the pool!!!!)

 

[SpeedRacer93]

Hi SpeedRacer93,

keep in mind that IGBTs have a voltage drop (VCE) and are therefore commonly used in circuits with higher voltages. For your purpose some power MOEFETs could be the better choice.

Thanks for pointing that out. I need to pull spec sheets on components. I stated IGBTs because of the AMP load with out really looking at all the spec. I am working to meet up with a friend that works with a electronics production firm here locally.

I am the mechanical engineer and project management type.