NMX‑EBT‑1000 / Rev 00 / IS 17855 · AIS‑156 / Noida · India 2026 · Product Page

NMX-EBT-1000 · ENGINEERED TO ORDER — EV BATTERY TEST SYSTEMS

A battery’s whole life, run in fast-forward.

Name: EV Battery Test System
Brand: Neometrix

EV battery test systems from cell to pack — regenerative cyclers with ±1 mV / ±0.05 % measurement, millisecond control, and impedance spectroscopy built into the cycling channel. Module and pack cycling to 1,000 V with drive-cycle replay, BMS validation, and chambers so every test runs at temperature. ≥90 % of discharge energy goes back to the bus, not into heat. Engineered to order — the reference configuration on this page has not yet been built.

Enquire — battery test Capability sheet (PDF)

Illustrative image, not a delivered installation — a battery test laboratory: a row of tall grey cycler cabinets with cable trays overhead, thick orange high-voltage cables dropping to a battery pack on a test bench, and a reach-in environmental chamber beside the bench

Fig · 01 Cycler cabinets, a pack under test and the chamber beside it — illustrative, not a delivered installation

Cell channel

0–300A · 0–6 V

Accuracy

±1mV · ±0.05 %

EIS

10mHz–10 kHz

Pack level

1,000V class

Regeneration

≥90%

ISO 9001 / 14001 Engineered to order IS 17855 · AIS-156 · IEC 62660 executed 17025-traceable calibration in scope of supply Noida · India

Overview

A battery answers slowly. The lab must ask precisely.

A cell reveals its quality over thousands of cycles and its ageing over years. A battery laboratory compresses that lifetime into weeks — and the compression only works if every question put to the cell is asked with millivolt precision, millisecond timing, and absolute repeatability. That is what a cycler actually is: a machine for asking the same precise question a million times.

Illustrative image, not a delivered installation — close-up of a cell test station: cylindrical and pouch lithium cells in spring-loaded four-wire test fixtures on a bench tray, with pairs of red and black sense and current leads dressed neatly to a connector panel

Fig · 02 Cell fixtures — force and sense separated, per channel — illustrative, not a delivered installation

Millivolts are the currency. The difference between a healthy cell and a degrading one is buried in millivolts of terminal voltage and micro-ohms of impedance. The cycling channels here measure to better than ±1 mV and ±0.05 % of current, sampling every millisecond, with force and sense wiring separated so cable drops never masquerade as cell behaviour.

Impedance is the early warning. A cell’s impedance rises long before its capacity visibly fades. EIS is built into the cycler — galvanostatic and potentiostatic, 10 mHz to 10 kHz, resolving to 1 µΩ — so the spectroscopy runs in the same fixture, on the same schedule, without ever moving the cell to a separate instrument.

The current must move like a vehicle. Drive-cycle replay demands current steps faster than any road event — the channels slew 10–90 % in under 3 ms, so an acceleration transient in the profile is a transient at the terminals, not a software ramp.

And the energy comes back: at least 90 % of every discharge returns to the bus. A resistor-bank lab pays for that energy twice — once buying it, once cooling it away.

Engineered to Order

Sized to the cells, packs and standards

Channel counts, current classes, pack-level power, chamber pairing and automation depth follow from what is being tested and which standards it answers to. The reference envelope here was engineered against India’s current EV-laboratory build-out; no order followed, so no delivered system is claimed.

Cell · Module · Pack

Three levels, one discipline

A 6 V / 300 A cell channel and a 1,000 V pack circuit are the same measurement philosophy at different power: four-wire truth, millisecond control, regenerative return — and channel paralleling bridges the levels when a big cell needs more current than one channel carries.

Tested at Temperature

The chamber is part of the test

Capacity at −20 °C, ageing at +45 °C, abuse limits beyond — battery behaviour is temperature behaviour. Cyclers pair with reach-in chambers at cell level and walk-ins at pack level, from the Neometrix climatic chamber line, so the thermal half of every standard is native, not improvised.

Architecture

Energy in a loop, truth in four wires.

The schematic below is the whole laboratory: the regenerative power loop that cycles without burning, the four-wire measurement that keeps cable drops out of the data, the EIS function living on the same channels, and the safety chain that watches all of it.

FIG · 03SYSTEM ARCHITECTURE · REGENERATIVE POWER LOOP · FOUR-WIRE MEASUREMENT · EIS ON-CHANNEL · SAFETY CHAIN

Fig · 03 Discharge energy circulates back through the regenerative front end; only losses are drawn from the grid — and every channel carries its own limits before the system-level chain even looks

Arc · 01

The Regenerative Loop

Charge flows from the bus into the cell; on discharge the channel inverts and ≥90 % of the energy returns through the active front end. The grid supplies only losses. At one bench this is tidy engineering; across a laboratory of hundreds of channels it is the difference between a modest supply and a substation — and between a ventilated room and a refrigeration plant.

Arc · 02

Four-Wire Truth

Every channel carries separate force and sense pairs to the cell tab. Current flows in the force pair; the sense pair carries none, so the measured voltage is the cell’s, not the cable’s. At 300 A even a milliohm of lead resistance would swamp the millivolts that matter — which is why the fixture, not the electronics, is where cell measurement is usually won or lost.

Arc · 03

EIS On-Channel

A small AC perturbation — galvanostatic or potentiostatic — is superimposed and swept from 10 mHz to 10 kHz, resolving impedance to 1 µΩ. Because it runs on the cycling channel, spectra can be scheduled into the life test itself: every N cycles, an impedance fingerprint — ageing watched as it happens, not discovered at teardown.

Arc · 04

The Safety Chain

Batteries store their hazard. Every channel enforces programmable voltage, current and temperature limits in hardware; above them sit contactor and fuse isolation, smoke and vent interlock hooks, a fire-panel interface and a defined emergency shutdown philosophy. The design assumption is simple: a cell will eventually misbehave, and the lab must already know what happens next.

Have a battery lab, cell cycler or pack test requirement? Send it across — clause-by-clause compliance matrix within two working days · [email protected]

Send tender spec

Specifications

Reference system, sized to your chemistry.

The parameters below describe reference cell-level cyclers and a pack-level envelope. Channel counts, current classes, power, chamber pairing and automation are settled against the cells, the packs and the standards at design review.

Illustrative image, not a delivered installation — a battery pack on a wheeled test trolley inside a walk-in environmental chamber, connected by thick orange high-voltage cables and a sense-wire loom to a bulkhead panel, with the chamber door open and cycler cabinets visible outside

Fig · 04 Pack cycling at temperature — the chamber is part of the test — illustrative, not a delivered installation

Where battery labs actually disappoint

Rarely in the brochure numbers. The quiet failures: fixtures whose contact resistance drifts until data scatters; discharge heat dumped into a room the HVAC was never sized for; a life test lost at cycle nine thousand to a power blip because resume logic was an afterthought; and safety added as accessories instead of engineered as a chain.

That is why this page dwells on the fixture, the regenerative loop, the per-channel hardware limits and the interlock chain — the parts that decide whether year three of the lab looks like year one.

Full specification — expand

System	EV battery test system — cell cyclers, module/pack cycling circuits, BMS validation, environmental integration, automation and safety chain · design, engineering, supply, installation, integration, commissioning, calibration and training
Cell Cyclers	Reference classes: 48 channels × 0–6 V / 0–300 A and 16 channels × 0–6 V / 0–50 A · independent channels · paralleling to raise current on any group of channels
Dynamics	Current rise time <3 ms (10–90 % of range) · data acquisition every 1 ms · drive-cycle replay from current or power profiles
Accuracy	Voltage <±1 mV, resolution 1 mV · current ±0.05 %, resolution 1 mA · four-wire (force/sense) connection per channel
EIS	Built into the cycling channels · galvanostatic and potentiostatic · 10 mHz–10 kHz · measurement resolution to 1 µΩ · schedulable within life tests
Regeneration	≥90 % of discharge energy returned via active front end · grid draw limited to system losses · correspondingly reduced cooling load
Module / Pack Level	Reference envelope 0–1,000 V · parallelable power stages to the hundreds-of-kW class per circuit · CC / CV / CP / CR modes · capacity & energy, DCIR, HPPC, cycle life, calendar ageing
BMS Validation	Cell-voltage simulation and fault injection · CAN communication · SoC/SoH profile testing against the pack’s own management system
Software	Independent control and monitoring of every channel · profile generation, import/export (CSV-class) · live and historical curves · offline simulation of profiles · LAN/Ethernet · resume-after-interruption so a 10,000-cycle test survives a power dip
Environmental	Cyclers paired with climatic chambers — reach-in at cell level, walk-in at pack level (see the Neometrix climatic & environmental test chamber line) · cabled through sealed bulkheads · thermocouple looms per DUT
Safety	Per-channel programmable V/I/T limits in hardware · over-voltage, over-current, over-temperature cut-offs · contactor + fuse isolation · smoke and vent interlock hooks · fire-panel interface · defined emergency shutdown philosophy · HV interlocked covers at pack level
Standards Executed	IS 17855 / ISO 12405-4 (pack & system) · IEC 62660 (cells) · AIS-156 Amd 3, AIS-038 Rev 2 (EV battery safety) · UN 38.3 (transport) · IEC 62619 · calibration ISO/IEC 17025-traceable, in scope of supply
Sourcing	Power stages, contactors and measurement front-ends are proprietary bought-in components of established manufacturers · Neometrix engineers and builds the system around them — fixtures, power architecture, measurement chain, chamber integration, automation, safety chain, installation, calibration and acceptance
Status	Engineered to order — reference configuration, not yet built · sized to the cells, packs and standards at design review

PDF · 1 page

EV Battery Test System — Capability Sheet

Tender Response

Send your specification — compliance matrix in two working days

Variants

Cell to pack, one measurement creed.

Tenders call these cell cyclers, battery cyclers, pack test systems or battery lab setups. What changes is the voltage, the current, and how much of the building the safety chain has to talk to.

Var · 01

Cell Cycler Banks

High-count channel banks — the 48×300 A and 16×50 A reference classes — with four-wire fixtures, on-channel EIS and reach-in chamber pairing, for cell qualification, grading and ageing studies.

Var · 02

Module & Pack Cycling Circuits

0–1,000 V regenerative circuits to the hundreds-of-kW class, drive-cycle replay, DCIR/HPPC characterisation and walk-in chamber integration — the pack proven as the vehicle will use it.

Var · 03

BMS Validation Rigs

Cell-voltage simulation, fault injection and CAN test harnesses that exercise the battery management system against faults no one wants to create in a real pack.

Var · 04

Turnkey Battery Laboratories

The full room: cycler banks, chambers, HV distribution, safety chain, fire interface, DAQ and automation — engineered as one facility, in the pattern of the Neometrix qualification-infrastructure line.

Applications

Where it applies.

Anywhere cells become products — and products must prove themselves faster than a battery ages.

A · 01EV cell & pack qualification to AIS-156 / AIS-038 and IS 17855

A · 02Cell ageing & life studies — cycle life, calendar ageing, EIS tracking

A · 03BMS development & validation with fault injection

A · 04Proving grounds, research centres & certification laboratories

A · 05Stationary storage & industrial cells to IEC 62619

A · 06Transport certification — UN 38.3 test sequences

FAQ

Common questions.

Plain-language answers from the engineering team.

Q · 01 Why does a battery lab need regenerative cyclers?

Because a cycler discharges batteries for a living, and that energy has to go somewhere. The old answer was resistor banks: every ampere-hour a cell gave up became heat in the room, which the air-conditioning then fought at further expense — the lab paid for the energy twice. A regenerative cycler inverts its power stage during discharge and pushes at least 90 % of the energy back onto the DC bus, where the next charging channel — or the grid — reuses it. At one bench the difference is a utility bill; at laboratory scale, with hundreds of channels cycling around the clock, it decides the size of the incoming supply, the cooling plant, and ultimately how many channels the building can host.

Q · 02 What is EIS, and why build it into the cycler?

Electrochemical impedance spectroscopy asks a cell how it responds to a tiny alternating signal across a sweep of frequencies — here 10 mHz to 10 kHz — and the resulting spectrum separates what a single DC resistance number lumps together: ohmic resistance, charge-transfer behaviour, diffusion. Impedance is the early-warning instrument of battery health; it rises measurably long before capacity visibly fades. Building it into the cycling channel — rather than owning a separate spectroscopy instrument — matters for a practical reason: the cell never moves. The same fixture, the same contacts, the same schedule; a spectrum every N cycles, automatically, so a life test produces not just an endpoint but the whole trajectory of ageing, resolved to a millionth of an ohm.

Q · 03 Why is four-wire measurement such a big deal at high current?

Because Ohm’s law works against you. Push 300 A down a test lead with just one milliohm of resistance and the lead drops 300 mV — three hundred times the ±1 mV accuracy the measurement claims. If voltage were sensed through the same wires that carry the current, the instrument would read the cable, not the cell. Four-wire (Kelvin) connection separates the two jobs: a force pair carries the current, and a dedicated sense pair — carrying essentially none — reads the voltage right at the cell tab. The corollary is that fixture quality becomes part of the measurement chain: spring pressure, contact cleanliness and lead dressing decide data quality as much as the electronics do, which is why fixtures are engineered here rather than improvised.

Q · 04 What do the Indian EV battery standards actually require?

Two families matter. AIS-156 (for L-category vehicles) and AIS-038 Rev 2 (for M and N categories) are India’s EV battery safety regulations, aligned with international practice and sharpened after real-world incidents: they demand proof against overcharge, over-discharge, short circuit, thermal exposure, vibration and mechanical abuse, with thermal-propagation requirements added by amendment. IS 17855 — India’s adoption of ISO 12405-4 — is the performance side: capacity, power, DCIR and HPPC, energy efficiency and life testing for packs and systems, while IEC 62660 covers the cell level and UN 38.3 governs transport. A laboratory built to execute these standards therefore needs precision cycling, programmable abuse boundaries, environmental conditioning and airtight data integrity together — which is exactly the combination this page describes. The standards are what the lab executes; certification itself belongs to the accredited bodies.

Q · 05 How does the lab stay safe when a cell fails?

By assuming it eventually will, and engineering backwards from that day. The first line is per-channel: programmable voltage, current and temperature limits enforced in hardware, so a runaway condition is cut off in the channel before any software has an opinion. Above that, contactor and fuse isolation physically separates a misbehaving device; thermocouples on the DUT feed limit logic; smoke and vent interlock hooks tie the test area into extraction; and the fire-panel interface plus a defined emergency shutdown philosophy determine, in advance, what trips, what isolates and what keeps logging. Chambers add their own layer for cells under thermal test. None of this is an accessory list — it is a chain, and it is engineered as one system because a battery laboratory must fail safe, not merely fail rarely.

Q · 06 Do you make the power electronics yourselves?

No — power stages, contactors and precision measurement front-ends are proprietary components from established manufacturers, selected for the duty rather than reinvented. What Neometrix engineers and builds is the test system: the four-wire fixtures where measurements are actually won, the regenerative power architecture, the channel and safety chain, the chamber integration, the automation and data layer, and the installation, calibration and acceptance that make results defensible. It is the same division of work as our chassis dynamometer and EMC laboratory pages — and to be straightforward: this configuration is engineered to order and has not yet been built, so nothing here is offered as a delivered reference.

↗

The EV test laboratory from Neometrix.

Battery, powertrain, environmental and electromagnetic qualification — engineered as one family at our Noida facility.

↗ Environmental

Climatic & Environmental Test Chambers

The chambers these cyclers test inside.

↗ Powertrain

E-Motor Test Bench

Where the pack’s energy goes next.

↗ EMC

EMI / EMC Test Laboratory

The electromagnetic half of EV qualification.

Browse all Neometrix product lines.

Get a quotation

Send your cells
and your standards.

The Projects desk replies within two working days with a clause-by-clause compliance matrix and a budgetary quotation. Write to [email protected] or use the form.

Enquire — battery test Capability sheet (PDF) +91 7777 876 876

ISO 9001 / 14001 ENGINEERED TO ORDER — EV BATTERY TEST SYSTEMS IS 17855 · AIS-156 · IEC 62660 · UN 38.3 ENGINEERED IN NOIDA · INDIA

A battery’s whole life, run in fast-forward.

A battery answers slowly. The lab must ask precisely.

Sized to the cells, packs and standards

Three levels, one discipline

The chamber is part of the test

Energy in a loop, truth in four wires.

The Regenerative Loop

Four-Wire Truth

EIS On-Channel

The Safety Chain

Reference system, sized to your chemistry.

Where battery labs actually disappoint

Cell to pack, one measurement creed.

Cell Cycler Banks

Module & Pack Cycling Circuits

BMS Validation Rigs

Turnkey Battery Laboratories

Where it applies.

Common questions.

The EV test laboratory from Neometrix.

Climatic & Environmental Test Chambers

E-Motor Test Bench

EMI / EMC Test Laboratory

Send your cells
and your standards.

Similar Products

Share This Page

A battery’s whole life, run in fast-forward.

A battery answers slowly. The lab must ask precisely.

Sized to the cells, packs and standards

Three levels, one discipline

The chamber is part of the test

Energy in a loop, truth in four wires.

The Regenerative Loop

Four-Wire Truth

EIS On-Channel

The Safety Chain

Reference system, sized to your chemistry.

Where battery labs actually disappoint

Cell to pack, one measurement creed.

Cell Cycler Banks

Module & Pack Cycling Circuits

BMS Validation Rigs

Turnkey Battery Laboratories

Where it applies.

Common questions.

The EV test laboratory from Neometrix.

Climatic & Environmental Test Chambers

E-Motor Test Bench

EMI / EMC Test Laboratory

Send your cellsand your standards.

Similar Products

Share This Page

Send your cells
and your standards.