Integration accounts for one-third of the manufacturing cost of power cells

Integration accounts for one-third of the manufacturing cost of power cells

The shift to electric cars continues to accelerate, driven by tighter carbon dioxide controls and more environmentally conscious consumers. Recently, The General Office of the State Council officially issued the New Energy Automobile Industry Development Plan (2020-2035), which gives development ideas and some indicators in infrastructure, technology, market and other dimensions, including the target of reaching 20% of the total sales volume of new cars of new energy vehicles by 2025.

As the market for electric vehicles explodes, so does the demand for high-performance batteries that power vehicles. Beyond that, old electric car batteries will eventually run out and be replaced. As a result, many technology companies are under pressure to bring battery-making devices to market quickly. While many factors determine the cost of a battery, the back-end process is one area where manufacturers can make progress in reducing costs. Specifically, it is the formation and testing process of the battery. It can account for as much as 20% of the cost of electric car batteries.

Integration accounts for one-third of the manufacturing cost of power cells
Design of high precision and high efficiency battery forming system

Battery formation and testing is a time-consuming process that involves multiple charges and discharges to activate the battery’s chemical properties for up to two days. This necessary process enables the battery to be put to practical use and is critical to ensuring the reliability and quality of the battery. This process is extremely slow, so it is one of the major bottlenecks that prevents the production of batteries from increasing and thus reducing the total cost of battery production. Partnerships between ev battery manufacturers and suppliers with expertise in chemical formation and test systems enable them to focus more on reducing the time and cost involved in this critical manufacturing phase while still maintaining the accuracy required for advanced battery chemicals.

In addition, both do so through a finely controlled charging and discharging process. The former acts as an “activation”, enabling the battery to begin to store and release electricity. The latter is to separate batteries with similar characteristics, so as to improve the consistency of the finished battery. The performance consistency of the battery is critical to the performance of the vehicle power battery pack.

To perform these electrical tests during the manufacture of lithium-ion batteries, highly integrated, high-efficiency and high-precision test equipment, such as ADI’s battery separation and charging-discharge integrated chip AD8452, is required. By integrating high-precision front-end amplifier and high-frequency PWM controller, ADI AD8452 provides a high-precision (up to 0.01% accuracy according to the specific design method), high-reliability and high-efficiency single-chip solution for the battery slicing system, while reducing the number of required components and the board area of the circuit board. Each PIECE of AD8452 can not only control the charge and discharge flow of up to 30A independently, but also can be connected in parallel to control a larger output current. ADI offers multiple parallel packages and provides staggered parallel design support to reduce current ripple during high current output.

By integrating a high-performance instrument amplifier/differential amplifier with a gain setting resistance network into the chip, the AD8452 provides high current and voltage measurement accuracy, and the accuracy of current and voltage control during charging and discharging largely determines the reliability of consistency control for lithium batteries. At the same time, ADI also has a unique current detector calibration and calibration technology. The consistency control level of lithium battery is improved comprehensively from many dimensions.

AD8452 battery integration solution

The manufacturing cost of lithium batteries is reduced in multi-dimensional integration

The capacity and formation of lithium batteries account for more than one-third of the manufacturing cost of lithium batteries. Manufacturers of lithium batteries are eager to improve energy efficiency in this area at a low cost while ensuring safety. This is mainly reflected in reducing the time required for the conversion, collecting and monitoring the parameter changes of lithium batteries with greater density from more dimensions, and making the charging and discharging process more efficient, power-saving, power-saving, equipment footprint, and cable usage and heating. To reduce battery costs, manufacturers need to take a holistic approach, first using the supplier’s system-level expertise to reduce the overall battery test circuit area and increase the number of channels.

Lithium-ion batteries are a long process

AD8452 can provide 50% more channels in the same space, thus expanding capacity and increasing battery output. In addition, compared with the traditional solution, the AD8452 based solution realizes the bidirectional flow of energy, that is, the recovery and reuse of current. During operation, the efficiency ratio of equipment can reach 92%, which can effectively reduce battery cost and save equipment running time.

The switching technology used in AD8452 can recover the battery energy during discharge, with an accuracy up to 10 times that of traditional switching solutions. Higher accuracy means more cells can be placed in the battery pack, which could help extend battery life for applications such as electric cars. AD8452 can save up to 50% BoM cost for charge/discharge board and about 20% system cost. It is worth mentioning that the device also has better detection and monitoring functions, which can effectively prevent overcharging and undercharging behaviors that may lead to battery failure, thus improving the safety of the manufacturing process.

As a single chip solution, AD8452 effectively reduces the number of devices needed and simplifies the design process and production testing process. Significantly reduces the time from the start of the design to the completion of the product to market. At the same time, because of the inheritance of high performance amplifier and gain resistance network, it is easy to achieve high measurement accuracy. In addition, a larger output current can be controlled by using THE AD8452 mismatch connection method.

Double AD8452 parallel 60A solution


The rapid growth of global demand for electric vehicles has brought great pressure to the industrial chain, so close cooperation between battery manufacturers and suppliers is what is most needed. Suppliers need to provide reliable, proven solutions that enable manufacturers to increase the efficiency of their systems. The best suppliers can help manufacturers bring these new features to market more quickly and ultimately allow battery and electric vehicle production to flourish. The benefits of working closely with vendors with system-level expertise and a broad product range go beyond acquiring more complex components and building blocks. It also gives battery makers access to reference designs for system architectures that are easier to adopt, making it three to four times faster to market than battery makers can develop and test systems from scratch.