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Breaking Through Barriers: High-Power Battery Manufacturing Enhanced with Innovative Test Tools

Efficient battery power delivery supporting radio communications during a military operation.

Lead-acid batteries have long been a staple in various industries due to their durability and efficiency. However, as demands for higher power densities and more environmentally friendly solutions increase, traditional manufacturing approaches face significant challenges. A leading battery manufacturer in the United States, is tackling these challenges head-on with innovative test tools that are revolutionizing high-power lead-acid battery manufacturing.

Group-31 batteries are renowned for their resilience in rugged environments and efficient power delivery. These batteries are crucial components in microgrids powering military communications systems and find applications in commercial trucking, cell-tower backups, marine vessels, powered mobility equipment, remote outposts, and renewable energy installations like solar and wind farms. With a commitment to environmental sustainability, this company employs a bi-polar approach in its manufacturing process, reducing lead usage by 40% compared to traditional methods.

However, the company faced obstacles in its expansion plans. Traditional testing equipment proved inadequate in meeting their evolving needs, leading to production bottlenecks, energy inefficiencies, and space constraints. Recognizing the urgency to address these challenges, the team sought out cutting-edge solutions to propel its growth trajectory.

Enter EA Elektro-Automatik (EA), now part of Tektronix, and its game-changing EA-BT 20000 series battery testers. This battery tester series offers triple-output capabilities and unparalleled power density, these testers are poised to revolutionize battery manufacturing. By implementing a combination of EA-BT 20360-80 (360V & 80A) and BT 20060-1000 (60V and 1000A) units, the company was able to streamline its testing processes, eliminate the need for multiple standalone testers, and significantly reduce floor space requirements.

Back view of EA-BT 20000 Triple 4U Battery Tester.  Each output can be used to test an

The advantages of EA's test tools extend beyond efficiency and space savings. With lightning-fast transmission speeds and regenerative capabilities, the EA-BT 20000 series ensures rapid throughput while minimizing energy consumption. Additionally, its versatility enables a wide range of testing applications for the batter workstream, from formation and state-of-health assessments to end-of-life testing.

The customer’s decision to invest in EA's modular testing solutions promises substantial returns. By doubling formation channels and optimizing testing processes, the company anticipates a significant boost in production output while slashing utility costs. With projected savings of approximately $151,000 per year in power consumption, the customer is poised for sustainable growth and continued innovation in high-power lead-acid battery manufacturing.

As the company sets its sights on future expansion and technological advancements, its partnership with EA Elektro-Automatik stands as a testament to the transformative potential of innovative test tools in overcoming industry challenges. With the power of cutting-edge technology at their fingertips, manufacturers are driving the evolution of lead-acid battery manufacturing towards a cleaner, more efficient future.

Read the full case study to learn all of the advantages leveraged with the EA-BT 20000 series battery tester.