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Battery Cycler with Data Analytics 

The Battery Cycler with Data Analytics (BCDA) is a comprehensive educational and experimental platform designed to study and analyze electric vehicle (EV) battery systems. Combining real EV components with open-source software and a built-in environmental chamber, this system provides users with the tools to conduct hands-on experiments, simulate real-world conditions, and perform in-depth data analytics. BCDA is ideal for institutions and research labs aiming to deliver practical skills and foster innovation in battery technology and electric mobility. 

Key Features

  • Integrated Experimental Platform with Real EV Components: Includes an actual lithium-based EV battery pack, smart BMS, and power electronics—all enclosed in a modular, scalable design that supports realistic battery cycling experiments.
  • Battery Cycler with Real-Time Data Logging: Supports programmable charge/discharge cycles using Constant Current (CC), Constant Voltage (CV), and Constant Power (CP) mode, C-Rate Mode and Battery Cycler mode. Monitors voltage, current, temperature, SoH, and SoC continuously with high-resolution data acquisition.
  • Environmental Chamber for Thermal Testing: Features an integrated environmental chamber capable of simulating ambient temperatures from –10°C to +60°C and humidity levels from 60%–90%, enabling the study of battery behavior under diverse environmental conditions.
  • Open-Source Control and Analytics Software: Users can configure tests, define control parameters, and modify algorithms using a PC-based software suite. The open-source nature of the system allows custom algorithm development for advanced research.
  • FPGA-Based Control Unit: A robust FPGA control board governs the cycler system, allowing precise, real-time regulation of testing parameters, ensuring high accuracy in all experiments.
  • Flexible Experimental Framework: Allows performance comparison of new and aged batteries, state-of-health (SoH) tracking, thermal response evaluation, and fuel economy benchmarking—all within a safe and controlled lab setting.
  • Designed for Indoor Use and Research: The enclosed, electrically safe design is ideal for indoor use in academic and industrial research labs. Includes full documentation and experiment protocols.
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Learning Module 

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Battery Charging & Discharging Characteristics

  • CC-CV and Constant Power charging behaviour analysis.
  • Discharge performance under varying load conditions.
  • Effect of different C-rates on efficiency and stress
  • Comparative analysis of partial vs full charging

Battery Health, Aging and Performance Analysis

  • State of Health estimation over repeated cycles
  • Capacity Fade and efficiency degradation studies
  • Fuel economy comparison of new and aged battery packs
  • evaluation of specific energy, specific power, and lifecycle cost

Thermal and Environmental Impact Studies

  • Battery performance at different ambient temperatures
  • Identification of thermal limits and safe operating windows
  • Validation of BMS temperature cut-off strategies
  • Impact of environment on charging speed and lifespan

Technical Description

  • Battery bank is housed inside a temperature- and humidity-controlled environmental chamber.
  • User configures test parameters such as charging mode, C-rate, cut-off limits, and temperature via PC software.
  • Control commands are transmitted to a microcontroller-based charge–discharge unit.
  • The cycler regulates voltage, current, and power in real time based on the selected profile.
  • Sensors continuously acquire electrical and thermal parameters.
  • Data is logged, visualized live, and exported for post-test analysis.
  • Open-source software enables users to modify algorithms and validate custom battery control strategies.
Ecosense

Technical Specifications 

Ecosense

Electrical Performance


ParametersSpecifications
Input SupplyAC 220 V ±10%, 50 Hz
Max Output Power1608 W
Voltage Output Range40 – 60 V
Current Output Range0 – 33.5 A
Accuracy±0.1% of Full Scale

* specifications can be customized as per user's requirement

Battery & Environmental System


ParametersSpecifications
Battery Rating48 V, 30 Ah
Max Charge / Discharge Rate1C
Battery Cycle Life>3000 cycles
Temperature Range of Environmental Chamber–10 °C to 60 °C
Humidity Range of Environmental Chamber60% – 90% RH

* specifications can be customized as per user's requirement

Control, Data & Protection


ParametersSpecifications
Controller32-bit ARM Cortex-M4
Data Logging RateAdjustable, up to 3.6 Msps
Data ExportCSV & image formats
CommunicationRS-485, Bluetooth
ProtectionSoftware cut-offs, DC relays, MCBs

* specifications can be customized as per user's requirement

Real world impact across Campuses

Recent Installations

Ecosense Establishes EV Lab at PSG GRD Museum of Science and Technology

Ecosense Establishes EV Lab at PSG GRD Museum of Science and Technology

July 10, 2025

Ecosense Sustainable Solutions, a pioneer in energy education and sustainability systems, has installed an advanced Electric Vehicle Lab at the...
Ecosense Establishes Advanced Electric Vehicle Lab at IET Lucknow

Ecosense Establishes Advanced Electric Vehicle Lab at IET Lucknow

June 17, 2025

Hands on Learning Platform for Electric Mobility, Aligned with India?s Clean Energy Future
Ecosense installed Battery Cycler (Charge - Discharge System) at BITS, Hyderabad

Ecosense installed Battery Cycler (Charge - Discharge System) at BITS, Hyderabad

April 29, 2024

In the realm of renewable energy and sustainable technology, efficient battery management systems play a crucial role. Recognizing this, Ecosense,...

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Frequently Asked Questions

We don't provide EIS as a standard. However it can be added on user's request.

The system is designed to cover most academic and applied EV battery studies, including charging–discharging behavior, C-rate analysis, aging, thermal impact, and SoH evaluation. With open-source software and configurable test cases, users can customize experiments to suit coursework, projects, and a wide range of battery research objectives.

Yes. The system includes layered safety through both software and hardware protection. User-defined cut-offs for voltage, current, temperature, SoC, and time prevent unsafe operation. Hardware-level protection using DC relays and MCBs ensures immediate isolation during fault conditions, making the system suitable for continuous laboratory use.

The primary advantage is realistic, data-driven understanding of EV battery behavior. It combines controlled cycling, environmental testing, and real-time analytics on actual battery packs. Open-source control, high measurement accuracy, and modular design make it ideal for hands-on learning, research, and long-term experimentation without relying solely on simulations.

Compared to basic chargers or electronic loads, the system is more complex and requires structured lab operation and supervision. It focuses on low-to-medium power EV battery packs, so it may not replace industrial-scale testing equipment. Dedicated EIS or cell-level chemical analysis also requires external instruments.

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