Battery Testing Solutions

Averna supplies advanced battery test systems, including regenerative battery test systems for electric vehicles, or cells, modules, BMUs, packs and energy storage solutions (ESS) to ensure optimum performance and safety. As a leading manufacturer of battery test equipment, we provide scalable solutions tailored to your needs.

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)

Additionally, our team is available for mechanical shock, leakage and vibration test integration.

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.

Button 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.

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™

By combining the most diverse hardware and software modules, Batterie Inspektor™ delivers innovative, automated, and digitalized battery testing at every stage of manufacturing.

With this flexible test platform, all modules can be adapted to their respective quality requirements. Manufacturing is simplified through a scalable and standardized framework for both new projects and upgrades.

With a wide range of test parameters, Batterie Inspektor™ ensures top quality products at every stage of manufacturing.

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

A flexible, all-in-one station designed for high-throughput end-of-line testing of EV battery packs and powertrain components. This platform supports:

Thermal and electrical testing
BMS verification
High-voltage insulation and leakage detection
Full traceability and data logging

Easily adaptable to new models and configurations, it's ideal for manufacturers needing a fast, future-proof solution.

EVSE Test Platform - Semi or Fully Automated

Purpose-built for EV charging infrastructure, this platform validates Electric Vehicle Supply Equipment (EVSE) under real-world conditions. Key capabilities include:

AC/DC charge testing and interlock validation
Communications protocol (e.g., ISO 15118, OCPP) testing
Electrical safety and durability tests

Available in semi or fully automated versions, this system ensures chargers meet both regulatory and in-field performance standards.

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

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.

Proven Successes in Battery Testing

Averna's collaboration with Gotion showcases our ability to deliver customized battery testing solutions. The system, based on the Batterie Inspektor™ framework, integrates NI's test instrumentation and is tailored to Gotion's requirements, ensuring meticulous testing of ESS performance.

Read our press release to discover how we helped this household name in batteries deliver perfection for multiple form factors with advanced machine vision technology.