Currently, mainstream lithium battery capacity testing equipment is mainly divided into five categories: benchtop charge-discharge testers, portable capacity testers, battery sorting machines, cycle life testers, and battery comprehensive performance testers. Each type adapts to different testing scenarios and accuracy requirements.
1. Benchtop Charge-Discharge Testers
Basic parameters and operating logic:
These testers operate according to the standard charge-discharge procedures specified in GB/T 31485-2015, calculating actual battery capacity through constant current and constant voltage charge-discharge cycles. Measurement error is usually controlled within ±0.5%. They can accommodate all standard lithium battery types, including coin cells, pouch cells, prismatic cells, and cylindrical cells, with capacity coverage from 0.01 Ah to 500 Ah.
Applicable scenarios:
Performance verification in lithium battery R&D laboratories.
Factory quality inspection for small-batch lithium battery products, generating standardized test reports.
2. Portable Capacity Testers
Core features:
Lightweight design, with a single unit typically weighing 1–3 kg and an internal rechargeable battery, supporting outdoor mobile operation. The operating threshold is low; users only need to connect the positive and negative terminals to quickly display remaining capacity, state of health (SOH), and other data. They are compatible with common 12 V–72 V low-voltage lithium battery packs and single cells with capacities from 1 Ah to 100 Ah, with measurement error around ±2%.
Applicable scenarios:
Rapid battery health inspection at electric vehicle after-sales service points.
On-site capacity verification for outdoor energy storage stations and emergency power supplies.
3. Battery Sorting Machines
Core functions:
These machines integrate capacity, internal resistance, and open-circuit voltage detection, automatically grouping batteries with consistent parameters into the same batch. They are dedicated equipment for mass production lines, with a single machine capable of processing 30 to 200 cells per minute, suitable for cylindrical, pouch, prismatic, and other single-cell types.
Applicable scenarios:
3C digital battery pack assembly lines, ensuring performance matching within the same battery group.
Early-stage sorting in power battery manufacturing, improving overall pack consistency.
For non-standard sorting trays, battery fixtures, or adapter components used in these battery testing and sorting systems, Hansheng Automation provides custom machining services based on customer drawings and required tolerances, helping maintain stable contact and accurate measurement during high-speed testing.
4. Cycle Life Testers
Core features:
These testers simulate actual operating conditions of lithium batteries, performing cyclic charge-discharge tests and recording capacity fade curves. They support multi-channel synchronous testing, with a single unit able to test 8 to 128 cells simultaneously, and test cycles can be customized up to several thousand times.
Applicable scenarios:
Life verification experiments in lithium battery R&D institutions.
Power battery life and reliability testing for new energy vehicle manufacturers.
5. Battery Comprehensive Performance Testers
Core functions:
These testers integrate multiple functions, including capacity testing, internal resistance measurement, AC impedance analysis, rate performance testing, and self-discharge rate detection. Their measurement accuracy is comparable to benchtop charge-discharge testers, and they can accommodate all standard lithium battery types.
Applicable scenarios:
Lithium battery performance research in universities and research institutes.
Comprehensive performance evaluation by third-party battery testing organizations.
Safety Operating Boundaries
When testing high-voltage lithium battery packs, personnel must hold a special electrical operation certificate. Non-professionals are strictly prohibited from touching high-voltage circuits.
Before testing, confirm that the battery is not in an abnormal state such as overcharge, over-discharge, or swelling to avoid leakage or fire risks during testing.
Waste batteries after testing must be temporarily stored and disposed of in accordance with GB 18597-2023, the Standard for Pollution Control on Hazardous Waste Storage.
