Battery Charge & Discharge Cycling Formation and Test Rectifiers are the most advanced version of our formation systems: bidirectional industrial power systems that can apply not only precise charging but also intelligent discharging with the same precise current and voltage control as charging.
Complex cycle programs such as Charge - Rest - Discharge - Rest - Recharge, required in battery manufacturing processes or deep capacity tests, are set up as fully automatic cycling (cycler) recipes thanks to REDARTI's proprietary microprocessor software. Our systems are built from 2 to 24 channels (e.g. 2, 4, 6, 8, 12, 16, 24 independent channels) at the required ampere and voltage ratings, in Switch-Mode or thyristor topology.
Fully Automatic Programmable Charge-Discharge Cycling (Cycler) Architecture
It has the technological capability to simulate a battery's entire life cycle in a factory or laboratory environment:
- Bidirectional Precise Current and Voltage Control: Just as in charge mode, in discharge mode the battery is discharged precisely with constant-current (CC) or constant-voltage (CV) limiting until it reaches the set lower voltage limit.
- Flexible Multi-Step Recipe Programming: The operator or factory automation can define an unlimited number of steps on the HMI/PC screen. For example: 5 h charge → 30 min rest → 2 h discharge → 30 min rest → full charge can be run as an automatic cycle.
- Real Ah / Wh Capacity Measurement and State-of-Health (SOH) Analysis: The net ampere-hours (Ah) and watt-hours (Wh) delivered by the battery during discharge are measured with millisecond data, instantly reporting the battery's true factory capacity and performance health (SOH – State of Health).
- Fully Independent Multi-Channel Flexibility: In cabinets with up to 24 channels, channel 1 can charge while channel 2 discharges; each channel runs its own recipe independently.
Advanced Discharge Technology Options: Resistive or Regenerative Architecture
- Resistive Load Discharge: The discharge energy is safely dissipated as heat through special internal/external stainless heavy-duty resistor banks.
- Grid-Tied Regenerative Discharge: With the optional regenerative power electronics architecture, the energy drawn from the battery during discharge is converted with high efficiency and fed back into the plant's electrical grid, delivering major energy savings across the facility.
Key Interface, Software and Hardware Features
- HMI and PC Graphics Software Integration: Charge and discharge curves (voltage/time, current/time, temperature/time) are displayed as live graphs and saved to a database on the colour touchscreen (HMI) or in PC software connected via Ethernet/Profinet.
- 100% Manual or Factory Automation (MES/SCADA) Control: Infrastructure for starting recipes manually or receiving work orders automatically from central factory software.
- Fully Protected Safety Architecture: Over-temperature, reverse-polarity connection and over-discharge (undervoltage) protection, cell temperature interlocks and emergency-stop integration.
Applications
- Battery Manufacturing Plants and Series Formation Lines: Electrochemical formation of finished plates and batteries with charge-discharge cycles, factory-exit capacity verification and quality control.
- Battery Testing, Certification and R&D Laboratories: Cycle-life testing, internal resistance and discharge-curve analysis to standards (EN, IEC, DIN, SAE).
- Battery Renewal, Regeneration and Desulfation Facilities: Plate regeneration and capacity recovery of deeply discharged, sulphated or capacity-depleted batteries through charge-discharge cycles.
- Logistics Traction / Forklift Fleet Management Centres: Periodic capacity measurement, discharge testing and cell-balancing maintenance of traction batteries.
- Electric Vehicle (EV) and Lithium Battery Pack Assembly Plants: Charge/discharge balancing of lithium battery modules, Ah capacity grading (cell grading) and testing processes.
