{"id":29211,"date":"2021-03-11T08:31:42","date_gmt":"2021-03-11T07:31:42","guid":{"rendered":"https:\/\/www.xyztec.com\/?p=29211"},"modified":"2026-04-15T17:21:12","modified_gmt":"2026-04-15T17:21:12","slug":"compact-bench-top-solution-for-battery-modules-up-to-900-mm","status":"publish","type":"post","link":"https:\/\/www.xyztec.com\/zh-hans\/compact-bench-top-solution-for-battery-modules-up-to-900-mm\/","title":{"rendered":"Compact bench-top solution for battery modules up to 900 mm"},"content":{"rendered":"<p>Test entire battery modules without the need to manually rotate the module mid-testing. A Sigma W12 with a custom slider work holder allows testing across the entire battery module. An ideal solution for R&amp;D to test batteries that would not fit for a standard Sigma bench-top system.<\/p>\n<p><!--more--><\/p>\n<h2>Custom solution for heavy wire battery modules<\/h2>\n<p>An electric vehicle manufacturer in the United States approached xyztec to develop a bond tester to test heavy wire battery module interconnects. Their needs:<\/p>\n<ul class=\"bulletimg\">\n<li>The use of a non-conductive pull hook for non-destruct and destruct <a href=\"https:\/\/www.xyztec.com\/knowledgecenter\/how-to-wire-pull\/how-to-wire-pull-wp\/\">wire pull testing<\/a> as well as shear capability for these same wire bonds<\/li>\n<li>Compact design for a reasonable price<\/li>\n<\/ul>\n<p>&nbsp;<\/p>\n<p>Xyztec has extensive mechanical, electrical, and software engineering capabilities. We can create solutions for any bond testing requirement like this custom battery bond tester by joining forces. Using a <a href=\"https:\/\/www.xyztec.com\/products\/sigma-w12\/\">Sigma W12<\/a> bond tester for 300 mm wafers as a baseline, we were able to develop this solution in less than 90 days.<\/p>\n<h2><\/h2>\n<h2><strong>Sliding work holder\u00a0<\/strong><\/h2>\n<p>If a battery module is too large for complete testing on a bench-top Sigma or Sigma W12, xyztec develops a unique custom solution. This custom work holder uses a sliding mechanism to test the entire battery module without manually rotating the module during testing.<\/p>\n<p>You can access all the bonds on your sample in one setup. The system is capable of destructive and non-destructive testing and comes with non-conductive tooling to minimize electrical shorts risks. There is specialty tooling design is available for pull test and shear tests.<\/p>\n<p><img fetchpriority=\"high\" decoding=\"async\" class=\"alignnone size-full wp-image-29325\" src=\"https:\/\/www.xyztec.com\/wp-content\/uploads\/Work-holder-slider.jpg\" alt=\"Work-holder-slider\" width=\"600\" height=\"400\" \/><\/p>\n<h2>Compact bench-top test solution<\/h2>\n<p>This bench-top system is compact and does not take up a lot of floor space. It comes with 2 heavy-duty stainless steel leg extensions to ensure stability and can support battery modules up to 35 kg. Easily control the stage motion through the software user interface.<\/p>\n<p><strong>\u00a0<\/strong><strong>\u00a0<\/strong><\/p>\n<h2><strong>Test volume up to 900 mm in X<\/strong><\/h2>\n<p>The custom pneumatic stage extension increases the testable reach in X beyond the standard 600 mm to a maximum of 900 mm. By extending the machine body and mounting the RMU farther from the rest of the system, the Y-axis is now 370 mm, a 120% increase relative to a standard Sigma.<\/p>\n<p>The stage extension doubles as the module work holder, enabling the user to fasten the sample during testing. Its unique pneumatic slide-action capability along the X-stage effectively creates 2 work areas. Switching between these areas can be done through our software during manual or automatic test modes. The operator can fully test battery modules using one or more look-down cameras to automate testing across the full module surface.<\/p>\n<p>&nbsp;<\/p>\n<h2><strong>Differences between a Sigma and this custom solution<\/strong><\/h2>\n<table width=\"665\">\n<tbody>\n<tr>\n<td width=\"332\"><\/td>\n<td width=\"138\"><strong>STANDARD <a href=\"https:\/\/www.xyztec.com\/products\/sigma\/\">SIGMA<\/a><\/strong><\/td>\n<td width=\"195\"><strong>SIGMA W12 + CUSTOM WORK HOLDER<\/strong><\/td>\n<\/tr>\n<tr>\n<td colspan=\"3\" width=\"665\"><strong>FORCE SENSORS<\/strong><\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Revolving Measurement Unit (RMU) Maximum Force (kgF)<\/td>\n<td width=\"138\">200<\/td>\n<td width=\"195\">10<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Rotational Shear Forces up to (kgF)<\/td>\n<td width=\"138\">10<\/td>\n<td width=\"195\">10<\/td>\n<\/tr>\n<tr>\n<td colspan=\"3\" width=\"665\"><strong>STAGES<\/strong><\/td>\n<\/tr>\n<tr>\n<td width=\"332\">X-stage (mm)<\/td>\n<td width=\"138\">370<\/td>\n<td width=\"195\">900<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Y-stage (mm)<\/td>\n<td width=\"138\">168<\/td>\n<td width=\"195\">370<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Z-stage (mm)<\/td>\n<td width=\"138\">168<\/td>\n<td width=\"195\">120<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">axis speed (mm\/s)<\/td>\n<td width=\"138\">50<\/td>\n<td width=\"195\">50<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Linear Encoder Resolution on Zero-Backlash drives (nm)<\/td>\n<td width=\"138\">30<\/td>\n<td width=\"195\">30<\/td>\n<\/tr>\n<tr>\n<td colspan=\"3\" width=\"665\"><strong>MECHANICAL<\/strong><\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Footprint X (mm)<\/td>\n<td width=\"138\">620<\/td>\n<td width=\"195\">1780<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Footprint Y (mm)<\/td>\n<td width=\"138\">558<\/td>\n<td width=\"195\">935<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Height (mm)<\/td>\n<td width=\"138\">608<\/td>\n<td width=\"195\">608<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">Weight (kg)<\/td>\n<td width=\"138\">80<\/td>\n<td width=\"195\">175<\/td>\n<\/tr>\n<tr>\n<td width=\"332\">System Type (Bench-top or Floor-mounted)<\/td>\n<td width=\"138\">Bench-top<\/td>\n<td width=\"195\">Bench-top<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>&nbsp;<\/p>\n<h2><strong>Your module fits, too!<\/strong><\/h2>\n<p>This <a href=\"https:\/\/www.xyztec.com\/features\/work-holders\/\">work holder<\/a> solution is just one example of our ability to generate <a href=\"https:\/\/www.xyztec.com\/products\/customization\/\">custom solutions<\/a> to meet unique customer requirements. If one of our existing test systems (i.e., Sigma or Sigma HF\/L system) does not meet your specific battery module needs. Please <a href=\"https:\/\/www.xyztec.com\/about\/contact\/\">reach out<\/a> to your local xyztec <a href=\"https:\/\/www.xyztec.com\/about\/representatives-distributors\/\">representative<\/a> to discuss your specific battery module testing requirements to learn more about which of our systems would best support your battery module bond testing requirements.<\/p>\n<p><img decoding=\"async\" class=\"alignnone size-full wp-image-29213\" src=\"https:\/\/www.xyztec.com\/wp-content\/uploads\/Battery-tester-with-modified-W12-plaform-.jpg\" alt=\"Battery-tester-with-modified-W12-plaform-\" width=\"600\" height=\"400\" \/><\/p>\n","protected":false},"excerpt":{"rendered":"<p>Test entire battery modules wi [&hellip;]<\/p>\n","protected":false},"author":18,"featured_media":29173,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[2955],"tags":[3846,3842,3845,3847,3849,3841,3844,3848,3245,3208,3840,3843,3850,3379,3398],"class_list":["post-29211","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news","tag-batteries","tag-battery","tag-battery-modules","tag-bench-top","tag-compact","tag-custom-solution","tag-heavy-wire","tag-non-conductive-pull","tag-shear-testing","tag-sigma-w12","tag-slider","tag-sliding-work-holder","tag-test-volume-900-mm","tag-wire-pull-testing","tag-work-holders"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Compact bench-top solution for battery modules up to 900 mm<\/title>\n<meta name=\"description\" content=\"This 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