2 Channel 20 Amp 6T Military Battery Testing

Industry: Aerospace and Defense

Testing Application: 6T Military Battery Performance and Safety Validation

A prominent company in the Aerospace and Defense sector approached Associated Environmental Systems (AES) in need of a specialized, battery-safe benchtop test system to replicate environmental conditions and validate the performance of 105Ah 6T military batteries.

The challenge? The client required a system capable of testing multiple high-capacity batteries simultaneously while managing a 20A live load. Key constraints included the need for seamless integration with a Maccor 4000 series tester, sufficient clearance for 2” diameter cabling, and robust safety protocols to mitigate risks during potential thermal runaway events.

The AES Solution

AES engineered the SC-512-4-SAFE, a high-performance benchtop battery test system featuring a custom-tailored ATP fixture built to meet the unique demands of this application.

• Custom-Tailored ATP Fixture: AES designed a custom tailored 2-channel, 20A ATP fixture featuring high-capacity full-extension shelving specifically reinforced to support 200 lbs. This tailored build allows engineers to safely slide heavy 6T batteries out of the chamber for easy wiring and inspection.
• Integrated Cycler Interface: To meet the client's specific workflow, the fixture includes a custom junction box and dedicated jumper cables designed for direct, plug-and-play integration with the Maccor 4000 tester.
• Precision Thermal Range: The chamber maintains a controlled environment from -20°C to 80°C with a stability of ±0.5°C, ensuring that OCV measurements and capacity verification are conducted under strict, repeatable conditions.
• AESONE CONNECT® Integration: Enables remote monitoring and data logging from a customizable dashboard, facilitating the tracking of voltage, current, and Coulomb counting in real-time
• AES SAFE Safety Features (-SAFE): To mitigate the risks of high-energy testing, the system is outfitted with a gaseous nitrogen (GN2) purge system and specialized safety sensors designed to activate instantly in the event of a thermal runaway. AES SAFE series keeps you safe up to EUCAR hazard level 7. 

Crafting Your Perfect Test Set-Up

This solution was custom-engineered to meet Aerospace and Defense testing demands in high-capacity battery validation and safety.

By combining heavy-duty reinforced shelving, integrated cycler interfaces, and rigorous safety fail-safes, AES delivered a system that seamlessly integrates with existing Maccor testing infrastructure while ensuring total reliability under live-load conditions. This project highlights AES’s commitment to designing advanced, customized test solutions that help engineers push boundaries—supporting innovation in the Aerospace sector and beyond.