Detect contamination that could cause defects. Improve battery cell productivity through high-speed testing.
To ensure the longevity and reliability of batteries, it is important to identify and address the root causes of latent defects during the production testing process. Small insulation defects, if left unchecked, can have a significant impact on the overall service life of a battery and increase the risk of fires. Two primary factors that contribute to insulation defects are contamination with metallic particles and small scratches that occur during the manufacturing process. By identifying and addressing these issues early on, we can ensure that the batteries produced meet the necessary quality standards and provide safe and reliable performance.
The BT5525 can prevent the shipment of batteries with latent defects that could lead to fires.
High-speed testing to increase production volume. Easy to add instruments while saving space. Invest in quality at a reasonable cost.
Ideal for insulation resistance testing before battery electrolyte filling
The BT5525 conducts insulation testing between electrodes prior to filling the cells with electrolyte, with a maximum test voltage of 500 V. Under specific test conditions, it also facilitates insulation testing between module/pack electrodes and the enclosure.
Detecting minuscule insulation defects caused by contamination (Break Down Detect function)
The proprietary BDD testing function is designed to detect even the smallest internal short-circuits caused by contaminants, such as metallic matter, before the battery cells are filled with electrolyte. By catching defective parts early on in the production process, the BDD helps reduce the risk of fires and accidents caused by overheating after the battery is shipped. Moreover, these tiny internal short-circuits can speed up battery degradation. By using the BDD function, the production of batteries with improved durability and electrical performance can be achieved.
Stable insulation resistance testing, even in noisy environments
Hioki utilized its extensive design expertise and insulation resistance tester measurement technology to successfully minimize the impact of external noise. This has led to the BT5525 delivering stable and consistent insulation resistance testing with a level of precision that allows for the detection of internal short-circuits caused by contamination.
Preventing testing do-overs due to erroneous judgments
The BT5525 offers a contact check function to verify that proper contact has been made with the circuit being tested. This is accomplished by measuring the capacitance between the measurement terminals, which includes both the stray capacitance and the capacitance of the circuit itself.
Ideal for insulation resistance testing before battery electrolyte filling
The BT5525 performs insulation testing between electrodes prior to the cells being filled with electrolyte, with a maximum test voltage of 500 V. In certain conditions that meet the requirements, it can also conduct insulation testing between the module/pack electrodes and the enclosure.
Shorten cycle times with a maximum charging current of 50 mA
The BT5525 boasts fast charging capabilities of up to 50 mA and rapid discharging of residual charge at 40 mA, significantly enhancing its charging and discharging performance.
This results in a boosted testing speed, with charging being approximately 25 times faster and discharging 4 times faster compared to earlier models. By doing so, it shortens the insulation resistance testing time for batteries, which are increasingly being produced with higher capacities.
*In comparison to Hioki’s INSULATION TESTER ST5520.
Compact footprint makes it easy to integrate the BT5525 into other systems
With its extensive product design expertise, Hioki has achieved high performance in a compact form factor. The instrument can be integrated into testing systems, thereby reducing their size. This enables manufacturers to utilize compact testing systems, maximizing limited production space.
Invest in quality at a reasonable cost
The BT5525‘s functionality and performance make it a cost-effective solution, as it was designed with careful consideration given to the specific requirements of battery insulation resistance testing.
A dedicated PC application allows for the monitoring of voltage and current fluctuations during testing.
The instrument has the ability to output a test voltage of up to 500 V, making it suitable for insulation resistance testing on batteries of all sizes, from the large batteries used in electric vehicles to small battery cells.
PC application for analyzing waveforms
Additionally, since data can be outputted in the CSV format, waveforms can also be reviewed using other applications, such as Excel.
Options
CLIP TYPE LEAD L2130
For HIGH terminal, banana / alligator clip, red, cord length 1.5m
CLIP TYPE LEAD L2131
For LOW terminal special triaxial / alligator clip, black, cord length 1.5m
OUTPUT CORD L9094
For analog output, banana plugs (red, black), cord length 1.5m
UNTERNIMINATED LEAD L2133
For LOW terminal, special triaxial / cut wire, black, cord length 5m
UNTERMINATED LEAD L2132
For HIGH terminal banana / cut wire, red, cord length 5m
UNTERMINATED LEAD L2132
For external control, double shielding, 9-pin / 9-pin, cord length 3m
Key Features
Contact check function reduces the number of false negatives caused by equipment issues.
BDD function for detecting minuscule short-circuits caused by contamination before batteries are shipped.
High cost performance thanks to accessible pricing, high-speed testing, and compact footprint.
Stable insulation resistance testing even in noisy environments.
Ideal for battery production lines.
Product Video
Dimensions and mass
215 mm (8.46 in) W × 80 mm (3.15 in) H × 306.5 mm (12.07 in) D, 2.8 kg (98.8 oz)
Using AR functionality
Scan the QR Code to the left on your Android or iOS device to access this page. Then select the AR button in the 3D model area to start your AR experience.
[ Precautions ] What you see in AR may differ from the actual product in terms of characteristics like size, colors, and materials. The following operating systems and browsers are recommended. [ iOS ] Safari on iOS 15 or later [ Android ] Chrome on Android 12 or later (AR enabled device)
To assure battery quality over the long term, it’s necessary to detect the causes of latent defects in testing processes on production lines. Minuscule insulation defects can eventually degrade battery service life and cause fires. The principal causes of insulation defects are contamination (with metallic matter) and minuscule scratches occurring in production processes.
The BT5525 can prevent the shipment of batteries with latent defects that could lead to fires.
This is introduction to the functions of the new “BATTERY INSULATION TESTER BT5525” for battery production lines. The BDD function, which monitors minute voltages and currents and detects foreign substances mixed in the production process, and a convenient PC application that allows you to view waveforms, will be explained while actually measuring!
Interface
Front Interface
Back Interface
External control and other communications interfaces
The BT5525 ships standard with LAN, RS-232C, and USB interfaces, allowing it to be connected to a PC or programmable logic controller (PCL). This capability can be used to control the instrument and retrieve test results.
Furthermore, the instrument provides external I/O terminals to facilitate instrument control and retrieval of instrument status and judgment results.
