A new integrated battery test system combines environmental chambers, cyclers, and fixtures into a single, pre-configured unit, designed to reduce setup and integration time. The system combines hardware and control software from Associated Environmental Systems (AES) and MACCOR Inc., allowing test facilities to begin operations shortly after delivery rather than waiting through traditional multi-vendor integration processes.
Battery testing across electric vehicles, aerospace, consumer electronics, and energy storage continues to expand, creating pressure on laboratories to validate more cells, modules, and packs in less time. In many cases, teams must coordinate multiple vendors and manage compatibility across separate chamber and cycler systems. These steps can extend deployment timelines and introduce communication or control challenges. The integrated system addresses these bottlenecks by unifying the electrical, safety, and control interfaces into a single, validated setup.
The system’s engineering integrates environmental control, cycling, and safety management. Chambers and cyclers are pre-wired, pre-programmed, and verified for compatibility before shipment. This configuration ensures that environmental conditions, current flow, and protection circuits operate cohesively under one control platform. Users can operate the system through AESONE CONNECT® and the Maccor Software Suite, which manage environmental and cycling parameters through synchronized interfaces.
Four configurations are available to meet varying current and channel requirements:
- FUSION-24-016-3200: 200-400A per channel, scalable to 16 channels
- FUSION-12-008-1600: 200-400A per channel, scalable to 8 channels
- FUSION-08-192-0192: 192 channels at 1A max current each
- FUSION-08-064-0960: 64 channels at 15A max current each
Each system operates from -20 °C to +80 °C with ±0.5 °C temperature stability. The higher-amperage configurations include regenerative capability with up to 90% return-to-grid efficiency. All units include integrated safety features, such as chamber interlocks and overcurrent protection, along with battery fixtures adaptable to different cell formats.
AES and Maccor have collaborated for over a decade, combining AES’s experience in environmental chamber engineering with Maccor’s background in battery cycler design. The system reflects this collaboration by uniting both domains in a single, pre-engineered platform intended for immediate deployment in research, manufacturing, and qualification environments.
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Filed Under: EVs, Featured, Test and measurement
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