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Battery Capacity Testing: All You Need To Know

Author: Site Editor     Publish Time: 2024-07-24      Origin: Site

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Battery Capacity Testing: All You Need To Know


Understanding battery capacity and its significance is essential for backup power systems that rely on battery performance.


What is Battery Capacity Testing?


Battery capacity testing is a method used to determine the amount of electricity a battery can hold. This testing is crucial for maintaining the performance and longevity of the battery. Capacity testing, also known as load testing or discharge testing, is a dynamic test in which a load is applied to a battery system for a specified period of time and the rated capacity is compared to the test results. Test results can vary significantly from the rated capacity and are affected by a variety of factors, such as battery age, usage history, charge/discharge rate, and temperature.


Why Battery Capacity Testing?


  • Ensuring Battery Health: Regular capacity testing helps assess the health of batteries. It identifies batteries that are losing capacity and need replacement.

  • Enhancing Battery Performance: By keeping track of battery capacity, users can optimize the performance of their batteries. It ensures that batteries are always in top condition, providing reliable power when needed.

  • Identifying Potential Issues Early: Early detection of capacity loss can prevent sudden battery failures. It allows users to take preemptive measures, ensuring that all devices powered by these batteries operate smoothly.


Manual Capacity Testing Issues


Manual Capacity Testing Safety Risks


  • Safety Risks

  1. Data Safety: When there are deteriorated batteries within the battery bank, some batteries are at risk of over-discharge, causing irreversible damage. Lead-acid batteries have a high likelihood of complete degradation within three months, while manual capacity testing cycles are typically one year, creating testing blind spots. Additionally, there is a risk of power loss during offline charge/discharge processes, which could lead to communication loss or business interruption at the site.

  2. Environmental Safety: Using dummy loads for discharge increases the risk of thermal hazards.

  3. Personnel Safety: The disconnection and reconnection of batteries during charge/discharge processes are complex, posing risks of short circuits, which can cause personal injury and equipment damage.


Manual Capacity Testing Standardization Challenges


  • Standardization Challenges

    Dispersed sites result in a significant workload, requiring a large number of maintenance personnel, leading to high operational costs. Large charging and discharging equipment is needed, and the entire capacity testing usually takes more than 24 hours. Manual recording is inefficient and prone to errors and misjudgments. Battery parameters and power parameters are separated, with no effective linkage for alarms during the capacity testing process.


DFUN Remote Online Battery Capacity Testing Solution


The solution stands out as a reliable tool for remote online battery capacity measurement. It supports 8–10 hours of long-term 0.1C online discharge, accurately calculating the discharge capacity of each battery and comparing it to the rated capacity to determine battery health.


DFUN Remote Online Battery Capacity Testing Solution


  • Extending Battery Life

  1. Pre-Charge Function: Balances bus voltage differences and prevents high-current charging impacts on batteries.

  2. Regular Battery Activation: Conducts regular activation and long-term balancing to improve battery consistency.

  3. Big Data Intelligence: Analyzes battery lifecycle data to provide maintenance suggestions and professional maintenance guidance to personnel.


  • Enhancing Safety

  1. Real Load Discharge: Generates less heat and is energy-efficient.

  2. Remote Non-Contact Testing: Eliminates personnel safety risks.

  3. Comprehensive Strategies: Employs up to 18 strategies for capacity testing process judgments, ensuring the reliability of online capacity testing. During testing, the battery and power parameters are linked, enabling timely warnings or alerts.


  • Reducing Carbon Emissions

    Saves 100 kWh of electricity per site for two capacity tests. According to the International Energy Agency, producing one kWh of electricity releases approximately 0.78 kilograms of CO₂. This translates to an annual reduction of 78 kilograms of CO₂ emissions per site (based on 2V 1000AH batteries).

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