From stacking each cell layer to confirming that a battery functions properly after assembly, precision matters at all steps of the EV battery-making process. Even the smallest mistakes can lead to costly errors, setting manufacturers back tens of thousands to even millions of dollars.
One of the most critical points in the assembly of an EV battery is the final quality control check before installing each battery into a vehicle. Once technicians seal the battery inside, they can’t make any more adjustments; either the battery works, or it fails. Widespread failures, as a result of even the smallest manufacturing errors, can lead to expensive recalls. As such, it pays to catch problems before batteries reach the final assembly line – which all comes down to the precision of your test equipment.
Over time, common test tools like digital multimeters (DMMs) and voltage input boards experience measurement drift. This drift leads to less accurate measurements during quality control, putting the final product at risk. However, there is a way to mitigate drift: calibrating test equipment regularly.
Many manufacturers manage the calibration of the tools necessary to build EV batteries by sending equipment to an external calibration lab. The downside of this outsourcing is that manufacturers may have to wait weeks to get their tools back. But, there’s a simple way to make calibration easier and faster: Install an in-house, high-accuracy reference standard like the Fluke 8588A.
In this application note, we’ll explain why calibration is uniquely important for the EV battery industry. We’ll also illustrate how the 8588A helps companies maintain top battery quality and avoid costly recalls, especially for teams that work directly in manufacturing, quality control, and research and development (R&D).
What Calibration Is and Why It Matters for EV Battery Manufacturing
Calibration is the practice of comparing the measurement values of a device under test (DUT) to a recognized standard and then adjusting the DUT until its measurements match that of the standard. Here’s a high-level overview of what the calibration process looks like in practice:
- Connect a DUT, such as a digital multimeter, to a reference standard.
- Run a test to simulate the same measurement on both the DUT and reference standard.
- Compare measurements. You’ll want to note how far off the measurements on the DUT are from the reference standard.
- Make adjustments to the DUT so that it matches or comes close to the reference standard.
- Run tests and make adjustments as needed to reduce DUT measurement uncertainty as much as possible.
This practice helps verify that your test devices always capture accurate measurements – the bedrock of quality assurance.
While it might not be top-of-mind for most manufacturers, calibration is one of the most important steps organizations can take to ensure top-tier production. Frequent calibrations (every few weeks or months, depending on the device) are especially important in environments where precision is a top priority and products are tested regularly.
If you use a voltage input board or digital multimeter to validate electrical circuits in an EV battery, those devices will lose accuracy over time. That means more room for error on the production line where even small deviations can spell disaster for manufacturers. Calibration restores the accuracy of your test devices so that you can always have confidence in your measurements and avoid costly missteps.
Using the Fluke 8588A for Better Batteries
Instead of sending off your equipment to a laboratory every time it needs to be calibrated, you can install a measurement standard like the Fluke 8588A Reference Multimeter in-house for quick and easy calibrations. This device will serve as your benchmark for comparing equipment measurements and gauging accuracy to determine what adjustments are needed. Having a reference standard readily available saves time, money, and makes it easy to complete frequent calibrations.
The 8588A offers several features that make it ideal for calibrating EV battery test equipment:
- High accuracy. Originally designed for calibration labs, the 8588A offers precision at 3.5 ppm accuracy for one year of DC voltage measurements. It’s trusted by scientists around the globe for its superior performance and accuracy, which translates into high quality assurance for your company.
- Long-term stability. The 8588A maintains its high accuracy for longer than most comparable reference standards on the market, meaning you can calibrate tools for longer with the same confidence as when you bought it.
- Low start-up costs make it possible for organizations to deploy multiple calibrators in case one fails. This is especially helpful when it comes time to calibrate your 8588A, which will need to be sent to a Fluke laboratory for precise adjustment.
- Ease of use. One of the 8588A’s standout features is its user-friendliness. It’s easy to set up and learn, and if your team needs a more in-depth walkthrough, Fluke offers training programs for teams of all sizes and experience levels.
In addition to all of these benefits, the 8588A features a unique digitization option, which allows for a broader range of test capabilities and offers fast results.
Digitization: Faster, Real-World Results
All that said, one of the most powerful features of the 8588A is its ability to digitize high-speed voltage data. This means your team can capture hard-to-detect surges like transients that may reflect quality issues. Digitization also allows you to emulate how a battery would respond to simulated, dynamic conditions to get a better picture of how it will perform in the real world.
For example, you could place a test load on the battery and use the 8588A to measure the battery’s response to see how quickly it recuperates. This feature is especially helpful for R&D experts working to improve battery charging cycles and lifespans, but it also helps quality control teams verify performance.
Not only does digitization give your team the opportunity to run more extensive tests, it’s also fast. The 8588A digitizes at rates up to five million samples per second, making it adept for running tests on tight R&D and manufacturing timelines.
Key Takeaways
Instrument drift can wreak havoc on product quality when you don’t keep it in check. To ensure instruments are regularly verified and calibrated — which helps you avoid costly errors — your team can calibrate in house with a reference standard like the Fluke 8588A.
The 8588A is uniquely poised to help EV battery manufacturers ensure consistent quality and make improvements during the R&D phase. Its accuracy, stability, and ease of use make it convenient for teams that operate outside of traditional calibration labs. Plus, digitization unlocks a host of test capabilities and fast performance to boost R&D cycles.
Why gamble with your product quality when you don’t have to? Investing in the tools to ensure accurate measurement takes the guesswork out of testing and gives you confidence in every battery that comes off the assembly line. In an industry with little tolerance for error, that kind of peace of mind is priceless.