REDARTI High-Current Battery Test Systems are professional test systems designed to carry out high-amperage shock-discharge tests (cold cranking amps / CCA simulation) on fully assembled batteries before final shipment, during the end-of-line (EOL) quality control stages of battery manufacturing plants. By detecting critical defects that can occur in production — reversed elements (polarity errors), weak cell welds, broken internal connectors and insufficient charge — within milliseconds, they prevent defective products from reaching the field 100%.
Our systems are built in thyristor-controlled (SCR / heavy-duty) or Switch-Mode (HF / IGBT) power electronics topologies according to customer demand and production-line requirements. The HRD Series has a standard high discharge capacity of 5,000 A and can also be built to order at currents above 5,000 A for special industrial or military projects.
Usable as a manual benchtop unit or integrated into fully automatic conveyor (in-line) systems, it runs extremely fast and precise tests with dynamic resistive load banks under PLC and HMI touch-panel control. It makes an instant "Pass/Fail" (TEST OK / ERROR) decision and diverts faulty batteries off the line (automatic rejection); test statistics and data are kept in the PLC memory and transferred to factory automation (MES/SCADA) via Ethernet/Wi-Fi.
Key Features
- Dual Power Electronics Architecture: A hardware-robust transformer-based thyristor-controlled (SCR) or a highly dynamic Switch-Mode (HF/IGBT) discharge power stage.
- High Shock-Discharge Capacity of 5,000 A and Above: Up to 5,000 A as standard, and tailor-made discharge power above 5,000 A for special projects.
- Automatic End-of-Line (EOL) Fault Detection: Instant diagnosis within milliseconds of production defects such as reversed cells, weak connector welds, internal-resistance collapse and incomplete charge.
- Automatic Decision Logic & Audible/Visual Alarms: Fast "Pass/Fail" decisions against set limits; alarm relays trigger the automatic rejection (push/sort) mechanism for faulty products.
- In-Line Conveyor & Pneumatic Integration: Stops batteries moving on the production belt with automatic pneumatic probes for continuous, uninterrupted series testing.
- PLC & HMI Touch-Panel Control: High-capacity PLC platform, colour touchscreen, the last 10 battery test records and live pass-rate tracking.
- Advanced Industrial Communication & MES Integration: Modbus RTU (RS485), Ethernet / Wi-Fi connectivity and 0-10V analogue control/feedback channels.
Applications
- Battery Manufacturing Plants: End-of-line (EOL) quality-control approval testing on starter (automotive/heavy-vehicle), traction and stationary battery production lines.
- Automotive & Heavy-Vehicle Plants: Final acceptance and performance testing of batteries entering vehicle assembly lines before they are fitted.
- Battery Service and Renewal Centres: Instant on-load performance and CCA testing of battery banks taken in for maintenance or overhaul.
- R&D and Quality Laboratories: High-current discharge simulations during product development and quality-standard verification.
