8 Channel 600 Amps Pouch Cell Testing

Industry: Electric Vertical Takeoff and Landing (EVTOL)

Testing Application: Validating various cell types and form factors for battery packs and modules designed for their eVTOL aircraft.

A pioneering leader in the Electric Vertical Takeoff and Landing (EVTOL) industry is actively developing next-generation battery technology to power their innovative aircrafts. These batteries face demanding operational profiles, requiring high power for takeoff and sustained flight, along with stringent safety standards and performance under diverse environmental conditions. Recognizing the need for reliable testing solutions, this organization relied on AES to develop a solution for them. 

The AES Solution

To address the demanding requirements of high-performance battery testing for the EVTOL industry, they adopted AES's newest addition to our All Test Platform series, the ATPHEAVY Cassette, which was fully integrated into our FD-527-7.5-SAFE chamber.

• Advanced Safety and Containment:The FD-527-7.5-SAFE chamber creates a secure, controlled environment for cycling cells under extreme conditions. Its design includes advanced temperature limited sheath heaters, airflow management, and containment features that meet EUCAR Level 7 safety standards, providing prevention and mitigation features in the event of thermal runaway.
• Extra Safety Precautions: As part of our commitment to safety, part of our EUCAR level 7 safety features is our reinforced door lock. The lock withstand 2,000 lbs of force. With this chamber, we added additional safety chains rated for 4,000 lbs to enhance security incase of a battery thermal event (BTE). 
• High-Current Testing Capability: ATPHEAVY Cassette supports 600 amps per channel, enabling the simultaneous high-current cycling essential for evaluating EVTOL battery performance under realistic operating conditions.
• Integrated Cassette System: Unlike traditional sliding shelves, our ATPHEAVY Cassette allows users to handle individual cassettes easily through injector latches on the base. These latches provide force to eject and insert the cassettes back into the base. Cabling is fixed within the chamber, significantly reducing cable length compared to traditional setups, where cables are wired throughout the fixture.
• Enhanced Connectivity: Each removable cassette is manufactured with a rear-mounted gold-plated copper buss bar that makes contact with a mating fixed buss bar within the ATP framework upon insertion. It features three product thermocouples and one safety thermocouple located at the front of the cassette for easy access.
• Safe and Serviceable Interface: The ATP/Cycler Interface Panel, located on the side of the chamber, provides isolated terminal posts for current-carrying wires and turret-style connectors for easy and safe interface with cycler sense wires.
  
  

Evolving Battery Testing Equipment for Leading Industries

By integrating the FD-527-7.5-SAFE and ATPHEAVY Cassette into their testing lab, this eVTOL industry leader enhances its ability to validate a wide range of battery cells with efficiency and precision. The removable cassette system simplifies testing across various cell types and form factors, while its high-current capabilities and advanced monitoring ensure accurate evaluation of battery performance and safety under real-world electric flight conditions. This strategic investment in cutting-edge battery testing technology is driving the future of electric aviation, reinforcing the industry's commitment to developing safe, reliable, and high-performance aircraft.

This customer purchased two FD-527-7.5-SAFE chambers

The FD-527-7.5-SAFE supports 8 channels at 600 amps per channel.

Cabling is fixed within the chamber, significantly reducing cable length compared to traditional setups, where cables are wired throughout the fixture.

Product thermocouples sit at the front of the chamber for easy access. 

ATPHEAVY Cassette allows users to handle individual cassettes easily through injector latches on the base. These latches provide force to eject and insert the cassettes back into the base.