Development of Low Cost Programmable Electrochemical Testing System for Lithium cells

The increasing adoption of lithium-ion batteries in various applications requires reliable and efficient testing systems to evaluate their performance and safety. This paper presents the design and implementation of a single-channel lithium-ion battery tester using MOSFET, SMPS, and an ESP32 microcontroller. The proposed system enables an accurate measurement of critical battery parameters such as capacity, discharge current, and voltage profiles. The MOSFET is used as an electronic load for controlled battery discharge and a current regulator for battery charge, while the SMPS provides a stable and efficient power source for system operation. H Bridge using MOSFETs is implemented to use a single circuitory for both charge and discharge and provide short circuit protection in case of system failure. The ESP32 microcontroller serves as the core of the system, handling real-time data acquisition, processing, and communication. Using its integrated Wi-Fi and Bluetooth capabilities, the ESP32 enables remote monitoring and data logging, improving usability and accessibility. Experimental results demonstrate the system’s capability to perform precise battery testing, with a focus on simplicity, cost-effectiveness, and scalability. The compact design and wireless connectivity make the proposed tester ideal for both laboratory research and field diagnostics. This work contributes to the development of modern battery evaluation tools by integrating advanced electronics with a user-centric approach. The proposed system is validated with 2Ah LNCA-Graphite based Lithium ion cells and the maximum error observed in the voltage and current are within 0.6% in nominal operating window of 3.3V to 4.0V. This system can also used for below 0V discharge without any additional setup.