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Battery load Testing

Feb 15, 2017

Load Testing

Load testing is used to verify that the battery can deliver its specified power when needed.

The load is usually designed to be representative of the expected conditions in which the battery may be used. It may be a constant load at the C rate or pulsed loads at higher current rates or in the case of automotive batteries, the load may be designed to simulate a typical driving pattern. Low power testing is usually carried out with resistive loads. For very high power testing with variable loads other techniques may be required. A Ward-Leonard controller may be used to provide the variable load profile with the battery power being returned to the mains supply rather than being dissipated in a load.


Note that the battery may appear to have a greater capacity when it is discharged intermittently than it may have when it is discharged continuously. This is because the battery is able to recover during the idle periods between heavy intermittent current drains. Thus testing a battery capacity with a continuous high current drain will not necessarily give results which represent the capacity achievable with the actual usage profile.


Load testing is often required to be carried out with variable load levels. This may simply be pulsed loads or it could be more complex high power load profiles such as those required for electric vehicle batteries. Standard load profiles such as the Federal Urban Driving Schedule (FUDS) and the Dynamic Stress Test (DST) specified by the United Sates Advanced Battery Consortium (USABC), in the USA, and the United Nations Economic Commission for Europe specification (ECE-15) and the Extra Urban Driving Cycle (EUDC) in Europe have been developed to simulate driving conditions and several manufacturers have incorporated these profiles into their test equipment.


ECE-15 Simulated Driving Cycle


While these standard usage cycles have been developed to provide a basis for comparison, it should be noted that the typical user doesn't necessarily drive according to these cycles and is likely to accelerate at least twice as fast as the allowed for in the standards.