Case Study Title: Battery Stack Thermal cycle Test System
Client Type: Energy Storage Solutions
Scope and Capabilities:
This project delivered a thermal cycle test system for battery stacks, developed and implemented in two stages. In the first stage, ATA provided engineering services for system design, including circuit modeling, heat exchanger sizing, pump and heater selection, and a full bill of materials. The system was configured to replace sulfuric acid with a safer glycol-based test fluid and to support closed-loop thermal management. In the second stage, the solution was expanded into a fully integrated test platform for dual-side battery stack thermal cycling. The system provided heating up to +70°C and cooling down to –20°C with ±3°C stability and an average ramp rate of 2°C per minute. It was designed for compatibility with customer-supplied hardware such as heat exchangers, heat rejection equipment, and battery test circuits, while ensuring safety through grounded enclosures and programmable control logic
Key Features:
Dual-side fluid temperature control with precision heating and cooling capability
Intermediate heat transfer circuit with dedicated storage tank, circulation pump, and fittings
Integration with customer-supplied heat exchangers, heat rejection hardware, and test circuits
Programmable safety controller with full guarding and electrically grounded machine frame
Movable machine frame with casters for flexible deployment
Data acquisition system supporting AI, AO, and DI/O channels with CSV data logging at 1 Hz
Automated control and thermal cycle programming via ATA’s FloINT software
Remote commissioning, validation, and tuning of software logic
Configured to support long-duration rental-based operation for extended testing campaigns
Deliverables:
Engineering services including circuit modeling, pump/heater sizing, and bill of materials for full system build
Initial setup, system configuration, verification at ATA’s facility, and remote start-up at the customer site
Rental of the integrated thermal cycling test platform, packaged and shipped with full safety inspection
Custom software integration with automated test sequencing, real-time monitoring, and data capture
Packaging, shipping, and optional insurance for long-term rental deployment
Documentation covering system design, operating parameters, and safety compliance
On-site training and remote support, including ongoing engineering assistance and maintenance provisions
