Combating Battery Degradation in EV Manufacturing with HIOKI Precision Tools
As the global shift toward electric vehicles (EVs) accelerates, manufacturers are under increasing pressure to deliver high-performing, reliable battery systems. At the heart of every EV lies its battery—arguably the most critical component impacting vehicle performance, safety, and longevity. Yet, one of the biggest challenges in EV manufacturing remains: early detection of battery degradation.
The Hidden Problem: Internal Resistance and Cell Degradation
Battery degradation often begins subtly. Even when voltage appears within spec, a cell may have elevated internal resistance— which is a key indicator of compromised performance. These early-stage issues are difficult to detect during mass production or field inspections but can lead to:
- Reduced driving range
- Faster capacity fade
- Thermal instability
- Warranty claims and recalls
Undetected, these issues become exponentially more costly down the line—especially once packs are assembled or vehicles are deployed in the field.
The Solution: High-Precision Battery Testing with HIOKI Equipment
To address this challenge, EV manufacturers and battery suppliers are utilising HIOKI’s industry-leading battery testers, such as the BT4560 and BT5525. These instruments are specifically designed to measure the internal resistance and voltage of lithium-ion battery cells with exceptional accuracy and speed.
About the HIOKI BT4560
The Battery Impedance Meter BT4560 can make EIS(*1) measurements quickly and easily in applications ranging from R&D to manufacturing. It delivers high-precision measurement capability for quality control of high-capacity batteries, and it can be expanded into an evaluation system for efficiently measuring multiple batteries. In addition, a new LAN interface simplifies the process of building a testing system, offering additional convenience.
Key Features
- EIS measurement frequency: 0.01 Hz to 1.05 kHz
- Simultaneous measurement of impedance, voltage, & temperature
- Convenient evaluation application software for R&D use
- Data compatibility with third-party equivalent circuit analysis software
- For production lines: LAN interface & advanced multi-channel solutions
About the HIOKI BT5525
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!
Key Features
Ideal for battery production lines
BDD function for detecting minuscule short-circuits caused by contamination before batteries are shipped
Stable insulation resistance testing even in noisy environments
High cost performance thanks to accessible pricing, high-speed testing, and compact footprint
Contact check function reduces the number of false negatives caused by equipment issues
By using HIOKI’s battery testers at the cell and module level, manufacturers can safeguard that only the highest-quality batteries move forward, hugely reducing the risk of downstream failures.
Driving Reliability from the Inside Out
In an industry where performance, safety, and brand reputation are everything, the ability to detect internal degradation early is not just a competitive advantage—it’s a necessity. With HIOKI’s precise battery testing solutions, EV manufacturers can strengthen their quality control processes and protect both their bottom line and their brand reputation.
