TIDUEY0A November   2020  – December 2025

 

  1.   1
  2.   Description
  3.   Resources
  4.   Features
  5.   Applications
  6.   6
  7. 1System Description
    1. 1.1 Li-ion Cell Formation Equipment
    2. 1.2 Key System Specifications
  8. 2System Overview
    1. 2.1 Block Diagram
    2. 2.2 System Design Theory
      1. 2.2.1 Feedback Controller
      2. 2.2.2 DC/DC Start-Up
      3. 2.2.3 High-Resolution PWM Generation
      4. 2.2.4 Output Inductor and Capacitor Selection
      5. 2.2.5 Current and Voltage Feedback
    3. 2.3 Highlighted Products
      1. 2.3.1 TMS320F28P650DK
      2. 2.3.2 ADS9324
      3. 2.3.3 INA630
      4. 2.3.4 UCC27284
      5. 2.3.5 REF50E
  9. 3Hardware, Software, Testing Requirements, and Test Results
    1. 3.1 Hardware Requirements
    2. 3.2 Software
      1. 3.2.1 Opening the Project Inside Code Composer Studio
      2. 3.2.2 Project Structure
      3. 3.2.3 Software Flow Diagram
    3. 3.3 Test Setup
      1. 3.3.1 Hardware Setup to Test Bidirectional Power Flow
      2. 3.3.2 Hardware Setup to Tune the Current and Voltage Loop
      3. 3.3.3 Hardware Setup for Current and Voltage Calibration
      4. 3.3.4 Lab Variables Definitions
      5. 3.3.5 Test Procedure
        1. 3.3.5.1 Lab 1. Open-Loop Current Control Single Phase
          1. 3.3.5.1.1 Setting Software Options for Lab 1
          2. 3.3.5.1.2 Building and Loading the Project and Setting up Debug Environment
          3. 3.3.5.1.3 Running the Code
        2. 3.3.5.2 Lab 2. Closed Loop Current Control Single Channel
          1. 3.3.5.2.1 Setting Software Options for Lab 2
          2. 3.3.5.2.2 Building and Loading the Project and Setting up Debug Environment
          3. 3.3.5.2.3 Run the Code
        3. 3.3.5.3 Lab 3. Open Loop Voltage Control Single Channel
          1. 3.3.5.3.1 Setting Software Options for Lab 3
          2. 3.3.5.3.2 Building and Loading the Project and Setting up Debug Environment
          3. 3.3.5.3.3 Running the Code
        4. 3.3.5.4 Lab 4. Closed Loop Current and Voltage Control Single Channel
          1. 3.3.5.4.1 Setting Software Options for Lab 4
          2. 3.3.5.4.2 Building and Loading the Project and Setting up Debug Environment
          3. 3.3.5.4.3 Running the Code
        5. 3.3.5.5 Lab 5. Closed Loop Current and Voltage Control Four Channels
          1. 3.3.5.5.1 Setting Software Options for Lab 5
          2. 3.3.5.5.2 Building and Loading the Project and Setting up Debug Environment
          3. 3.3.5.5.3 Running the Code
        6. 3.3.5.6 Calibration
    4. 3.4 Test Results
      1. 3.4.1 Current Load Regulation
      2. 3.4.2 Voltage Load Regulation
      3. 3.4.3 Current Linearity Test
      4. 3.4.4 Voltage Loop Linearity Test
      5. 3.4.5 Bidirectional Current Switching Time
      6. 3.4.6 Current Step Response
  10. 4Design and Documentation Support
    1. 4.1 Design Files
      1. 4.1.1 Schematics
      2. 4.1.2 BOM
    2. 4.2 Tools and Software
    3. 4.3 Documentation Support
    4. 4.4 Support Resources
    5. 4.5 Trademarks
  11. 5About the Author
  12. 6Revision History

1.1 Li-ion Cell Formation Equipment

The battery tester equipment includes a wide variety of equipment used to test single cells, battery modules, and high-voltage battery packs. Various tests need to be performed to validate the performance, capacity and safety of lithium-ion or other types of battery cells. Battery formation represents one of the critical steps in cell manufacturing. This process requires precision charge and discharge to a single cell to form solid electrolyte interface (SEI) layer. Cell grading and electrical testing evaluate the capacity and internal resistance of each cell. These tests require accurate current and voltage charge-discharge profiles and real-time data logging to capture detailed performance data.

Typical test equipment requires precision bidirectional power supplies and data acquisition systems to perform highly accurate current and voltage charge or discharge of a battery cell, often better than ±0.05% of full scale. With growth in battery capacity and more integrated multifunction test systems, a multichannel power supply achieves a higher volume of test channels for battery cells.

Two approaches can be used to manage charge-discharge cycles and provide precise testing conditions. Table 1-1 shows the difference between the two approaches:

Table 1-1 Analog and Digital Control
ASPECT ANALOG CONTROL DIGITAL CONTROL
Control Logic Hardware-based feedback loops using analog components Software-based algorithms running on DSP
Flexibility Fixed configurability; changes require hardware modifications Highly configurable through software; simple load compensation and supports multiple test profiles
Complexity Simpler design for basic functions but grows complex for advanced features More complex software development but simpler hardware for scalability
Response Time Fast, continuous response due to analog feedback Fast depends on microsecond latency, ADC and MCU speed
Precision High precision and sensitive to component tolerances and drift High precision with proper ADC resolution and calibration; less prone to drift
Data Logging Limited; requires additional circuitry for data acquisition Built-in data logging through MCU, enabling detailed analysis and traceability
Cost Lower for simple systems; higher for complex, high-precision designs Cost-effective for scalable, feature-rich systems

The TIDA-010086 reference design uses a digital control approach to create a multichannel, synchronous buck converter based on TMS320F28P650DK MCU and a 16-channel, integrated PGA, SAR ADC to achieve high accuracy, fast response, and high signal-chain density design.