Battery Testing Solutions

Custom Battery Testing Systems for Your Production Needs

At Averna, we engineer custom battery test systems designed to validate everything from coin cells and micro-batteries to EV battery cells, modules, BMS and packs.

We specialize in thermal and electrical testing, including:

Overcharging & forced discharging
Battery (cell) cycling
High and low temperature verification
Temperature cycling
Short-circuit, resistance, and insulation testing
BMS functional verification & validation
Optical inspections for miniature defects
Electrochemical Impedance Spectroscopy (EIS)

Cell Sorting and Micro-Level Optical Inspection

First, there is the fully automated cell sorting process in combination with the optical inspection of the individual cells. This includes assembled module and battery pack testing. Some tests may include:

Charge and discharge cycles
Open Circuit Voltage (OCV)
AC Internal Resistance (ACIR)
DC Internal Resistance (DCIR)
High Voltage insulation testing
Leak testing
BMS application tests

Second, we focus on the automated optical inspection of individual cells and assembled modules or pack products. Our systems can detect visual defects on a micron level (µm) that may have occurred during the cell formation or assembly process. This ensures only compliant and high-quality cells proceed to the next manufacturing stage.

Battery Cell Testing for Micro-Battery Applications

Miniature batteries such as button cells require highly precise validation due to their small form factor and use in critical devices such as medical wearables and portable electronics.

Averna integrates dedicated button cell testing capabilities into automated battery validation platforms to ensure the electrical integrity and mechanical quality of each micro-battery before final assembly.

Industries We Serve

Battery testing requirements vary significantly across sectors. Averna has deployed systems across primary verticals, each with distinct performance and compliance demands.

Cell, module, and pack validation with BMS verification and thermal testing for high-voltage EV powertrains at production scale.

ESS performance validation, EVSE testing, data center testing and power quality analysis for grid-tied and industrial energy systems.

Battery validation for powered medical devices, wearables, and implantables, with full traceability and certification support.

Electrical integrity and optical inspection for button cells and micro-batteries used in portable and connected devices.

EoL battery and powertrain testing, traction & coupling validation for rail vehicles, with fast ramp-up across sites.

Battery and power system validation for eVTOL, avionics, and defense platforms long program lifecycle support.

Averna's Battery Testing Equipment

Testing batteries isn't just a complex process. The stakes are high. This is because of the risks of thermal runaway, inconsistent test data and long cycle times. Manufacturers are under increasing pressure to validate performance, so it's important to be backed up by experts in the field.

Modular and Scalable Battery Testing with Batterie Inspektor™

A modular, scalable platform for automated cell, module, BMU, and pack testing across every stage of manufacturing.

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EV Battery EOL Testing with our EV Power Components End of Line Test Platform

All-in-one EOL station for high-voltage EV battery packs and powertrain components, with BMS verification, insulation testing.

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EVSE Test Platform — Semi or Fully Automated

Validates EVSE hardware under real-world conditions, including AC/DC charge testing, ISO 15118/OCPP protocol verification, and electrical safety.

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A Flexible Approach to Battery Cell, Module, Rack or Pack Testing

By leveraging our extensive instrumentation knowledge, Averna designs battery testing systems with no limits, aside from the ones you set. We will integrate the appropriate equipment for your validation needs, including battery cyclers, climate chambers, thermoregulation units and high-voltage instrumentation.

Flexible Fixturing Architecture

The Secret Recipe for Successful Battery Testing by Averna Each design is unique to meet the exact requirements of any application but leverages a flexible fixture design. This allows you to save costs by seamlessly testing and validating different products and variations by reusing the same test hardware and only exchanging the modular fixtures. This also limits any downtime in the case of a destructive cell failure.

By exchanging the fixture easily, tests can continue to run while the repair happens in parallel.

Battery Formation and Cycling Validation

During the battery formation phase, cells undergo controlled charge and discharge cycles to stabilize their chemical composition and prepare them for reliable operation. Averna offers high-precision battery cyclers that enable manufacturers to perform these processes with rigorous control over voltage, current, and temperature.

Our automated test systems execute reproducible cycling profiles while continuously monitoring electrical behavior and thermal response. Combined with environmental control and advanced measurement instruments, our validation platforms help manufacturers assess the long-term reliability of batteries and confirm that products meet demanding industry standards before they go into production.

Battery Test Data and Automation

Battery validation generates large volumes of electrical and thermal measurement data. Averna's software environment manages test execution while capturing detailed data throughout the validation process.

Test sequences coordinate the operation of cyclers, measurement instruments and environmental equipment while continuously recording system parameters. Engineers gain clear visibility into battery behavior during validation and can quickly identify anomalies or performance deviations.

SMART Safety Monitoring System

Battery testing starts with a safe solution. A battery can become dangerous on its own, but by adding the comprehensive test cases specified by the different norm standards makes it nearly impossible to accomplish safely. A modular test system contains multiple independent operating devices collaborating together. Our SMART safety monitoring system oversees all individual components and manages failures safely by isolating each one. This permits the system to be shut down safely.

3Dcover-CS-EV-Battery-Cell-Quality-Screening-for-Remanufacturing

In the automotive industry, a leading EV battery remanufacturer partnered with Averna to automate the screening of incoming battery cells and ensure consistent quality assessment at scale. The solution combines guided workflows, precision fixturing and parallel test execution to support high-throughput remanufacturing operations.

Automated validation of OCV, ACIR and electrochemical impedance (EIS) ensuring accurate qualification of battery cells
PXI-based architecture enabling true simultaneous testing with parallel sequencing, maximizing throughput and minimizing downtime

This approach standardizes battery cell evaluation while improving measurement reliability, reducing operator dependency and enabling scalable remanufacturing workflows.

8 parallel EIS tests

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