A new pack only earns its warranty if somebody measured it first. Every unit that leaves our workshop goes through a fixed protocol at cell, module and pack level — not a spot check, and not a visual once-over.
What we verify
- Capacity – full charge and discharge at controlled temperature, with the delivered amp-hours recorded against the nameplate figure.
- Internal resistance – measured per module so the spread across a pack stays tight; a pack is only as good as its weakest block.
- Insulation and isolation – high-voltage paths checked against the chassis and against the low-voltage harness.
- BMS and communication – live data on a bench rig: cell balance behaviour, fault flags, CAN responses under load.
- Thermal behaviour – temperature rise under sustained discharge and the fan or liquid loop response that goes with it.
- Mechanical and sealing – enclosure integrity, torque audit, gasket and connector seating.
Why pack-level validation matters
A cell that tests well on its own can still be the wrong cell for a pack. Modules in a hybrid battery age unevenly: the blocks nearest the cooling intake behave differently from the ones at the far end, and mismatched cells are where packs usually fail. Testing at pack level is the only way to see that before the customer does.
Without pack-level validation
- Capacity claims that collapse under real load
- A single weak module dragging the whole pack into balance faults
- Fault codes that appear weeks after fitting
- No baseline to argue a warranty claim against
With pack-level validation
- Measured capacity and resistance on the test sheet you receive
- Modules matched by generation, capacity and resistance before assembly
- Faults surfaced on the bench, not on the road
- A serial-numbered record you can quote back to us
The test programme
Safety
Overcharge and over-discharge protection, short-circuit behaviour, insulation resistance at high voltage, and abuse tolerance of the enclosure and internal structure.
Environment
High and low temperature operation, thermal cycling, humidity exposure and vibration profiles that stand in for a few thousand miles of bad road.
Electrical performance
Capacity, energy efficiency, rate capability at different C-rates, cycle behaviour over extended charge and discharge, and voltage stability at the pack terminals.
Ageing and final inspection
Capacity on day one is not the number that matters. Each pack is held through a high-temperature soak and then rested at room temperature before it is tested again, so that a unit which is going to drift does it while it is still in our building. Only packs that hold their figures after ageing are packed.
- Full functional test repeated after the ageing cycle
- Capacity and resistance sheet matched to the pack serial number
- Torque, sealing and connector audit, then a final visual sign-off
- Nothing ships without a test record attached to its serial number
What you receive
- Measured capacity, internal resistance and balance figures
- BMS fault history cleared and re-checked before dispatch
- Ageing data for the specific pack, not a batch average
- Serial number registered against your warranty period