[Customer Case] Electric Assist Bicycle Battery System Testing

Battery System and Power Control Unit Testing

Related FaithTech resources: FT8330.

Electric assist bicycles successfully combine the health and environmental benefits of traditional bicycles with the ease and efficiency of motorcycles, creating a brand new way of travel and lifestyle. The heart and brain—the battery system and power control unit—have reliability that directly determines riding safety and experience. How can one build a comprehensive, accurate, and reliable testing defense line under the premise of high efficiency? FaithTech's test solution, with its professional instruments and deep insights, provides a benchmark answer for customers.

Below is a case study sharing the application of FaithTech test equipment in electric assist bicycle battery systems and power control units.

Battery Test Requirements

A globally renowned manufacturer of home appliances and consumer electronics provides micro-mobility battery solutions. Their battery testing standards are as follows:

1. EN50604-1: European Committee for Standardization standard for lithium batteries for light electric vehicles.
2. UN38.3: Mandatory international transport regulation established by the United Nations, Section 38.3 of the "Manual of Tests and Criteria".
3. IEC62133-2: International general safety standard issued by the International Electrotechnical Commission for lithium batteries for portable devices.

FaithTech Solution

01 FaithTech Cell Simulator FT833024R-6-3: The "Brainpower" Examiner for the BMS System

• Precise Simulation, Insight into the Core: It accurately simulates key parameters such as battery SOC, depth of discharge, open circuit voltage, and internal resistance. During the R&D phase, it comprehensively tests whether the performance and protection functions of the power control unit respond precisely as designed.
• μA-Level Static Power Measurement: With its ultra-high precision measurement capability down to the microamp level, it easily captures the minimal power consumption of the BMS in standby mode, providing key data support for extending bicycle range and optimizing standby time.
• Excellent Dynamic Performance: Its dual current range design and high sampling rate ensure fast and accurate data capture under various operating conditions, from stable operation to sudden transient changes, meeting complex testing requirements.

02 Programmable DC Power Supply FaithTech FTP9060-300-75: The "Stress" Tester of Safety Boundaries

• Overcharge Test, Preventing Hazards: By simulating abnormal charging conditions, such as applying voltage or current far exceeding standards, it rigorously tests the battery's tolerance under extreme circumstances, observing whether it ignites or explodes. This provides the strictest validation for product safety design.
• Capacity Test, Accurately Assessing Lifespan: It measures the battery's actual capacity using a constant current charging method. By comparing this with the nominal capacity, it precisely calculates the battery's degradation rate, providing an authoritative basis for product quality assessment and lifespan prediction.

03 Programmable DC Electronic Load FT63230E-150-300: The "Terminator" of Performance and Limits

• Over-discharge Test, Verifying Discharge Performance: It simulates abnormal discharge conditions, rigorously testing the battery's voltage and temperature changes during over-discharge, as well as its recovery capability, assessing the degree of damage to the cells.
• Short Circuit Test, Building the Final Defense Line: It directly simulates the dangerous condition of an external short circuit, monitoring the battery's rapid temperature rise and current surge in real time. It verifies whether the internal protection device can instantly disconnect the circuit, thereby preventing safety incidents.

The equipment selection in this case accurately reflects the core advantages of FaithTech products: high precision, high reliability, and deep development capabilities oriented towards practical applications. FaithTech provides not only instruments but also a complete solution ranging from cell simulation and stress testing to limit verification, helping customers firmly secure the safety and performance baseline of their products throughout the entire process from R&D to quality control.

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FaithTech is a company specializing in the field of new energy power electronics testing and simulation instrumentation. We provide world-class, precise, high-quality full-series test & measurement power supplies, electronic load equipment, and test solutions. Leveraging profound technical accumulation, FaithTech was among the first in the industry to introduce over 10 high-level product series, including high-density high-power electronic loads, wide-range DC test & measurement power supplies, and high-performance high-power bidirectional DC power supplies, achieving performance indicators that reach international leading levels and are sold well in developed countries overseas.

FaithTech is committed to technology frontiers and independent R&D, holding nearly 100 independent intellectual property rights and having obtained CE, ROHS, and ISO 9001 international quality management system certifications.

FaithTech has been honored as a "National Specialized and Sophisticated 'Little Giant' Enterprise," a "National High-Tech Enterprise," a "Major Drafting Unit for 4 National Standards including 'High-Power Switching Power Supply Technical Specifications,'" and a "Specialized and Sophisticated SME." With reliable product quality and enthusiastic service, FaithTech has established long-term cooperative relationships with leading companies in the industry.

FaithTech – A High-End Test & Measurement Power Supply, Electronic Load, and Automated Test Integrated Solution Manufacturer