High-Voltage Battery Systems
Explore Our Comprehensive Battery Testing Services
Excel Engineering’s globally recognized Battery Tech Center in Mount Ayr, Iowa, includes > 30 battery test cells with comprehensive capabilities for your most demanding projects. We test batteries up to 2,000 Volts and 1 MegaWatt to support the development of electric, hybrid, and stationary power systems.
Electric & Hybrid Vehicles (xEV)
Our facilities specialize in developing hybrid systems and supporting a wide range of electrified vehicles.
If it’s POWERTRAIN related, Excel Engineering is testing it. Helping you maximize performance, efficiency, and value
Energy Storage Systems Stationary Power / BESS
We provide comprehensive testing for both commercial and residential Energy Storage Systems (ESS), from individual cells to full battery packs and systems.
Industrial Vehicles / Forklifts Material Handling / Tugs
UL583 TPTDP – Lithium-ion battery drop-in testing for: •Material handling equipment •Forklifts •Industrial vehicles
CAN integrated testing
E-Axle / EDM / EDU / E-Motor / Power Electronics
We deliver advanced testing solutions for critical components of electrified vehicles, including: •E-motors •E-axles •Electric drive modules (EDMs) •Electric drive units (EDUs) •Inverters •Power Electronics
Battery Abuse and Severe Environment Testing
•Nail Penetration •Thermal Propagation •Crush / Drop •Fire Resistance (ECE R100) •Vent gas analysis •Altitude @ 48,000′ •Over Charge •Short Circuit – State of the art @ 4mΩ
Power Management, Generation, Storage & Feed
We offer specialized testing for inverters, Battery Management Systems, and other power electronic systems including power management, generation, storage, and feed applications.
Testing Certifications & Standards:
• UL583 TPTDP approved (only one in the world other than UL)
• DNV Certification
• UN38.3
• ECE R100
• IEC 60529 • IEC 60068 • IEC 62619
• SAE J2424 • SAE J2929 • SAE J1798
• MIL-PRF-36565 • MIL-STD-810
• ISO 20653 • ISO 16750 • ISO 6469
- Advanced Simulators – We use advanced AV900 and ABC 150 Battery Simulators capable of 1000A, 900V, and 250kW. Our hardware includes 48 channels of high-voltage measurement.
- Controlled Environment – Our test chambers are temperature-controlled from 70°F to 140°F, with insulated enclosures capable of -40°F to 85°F. We use liquid cooling carts to provide precise pack temperature control and a 60 kWhr liquid loop to remove heat during testing.
- Comprehensive Safety – Our test cells feature passive and redundant active safety systems, including an automatic CO2 system for effective flame suppression and a physical barrier separating operators from the high-voltage test articles.
- DV & PV Test Plans – Full responsibility, Abuse, Durability, Environmental
- Ventilation – Our facilities include continuous fresh air ventilation and a depressurized chamber for safety.
- Altitude Simulation – For Operation and Shipping
- Chemical Emissions – Off-Gas volumetric analysis and quantification
- Video/Time-Sequenced Data Capture – High-speed video and time-sequenced data capture are utilized for detailed analysis of abuse and safety testing. This yields deeper insights into battery performance and failure modes and enables remote monitoring.
MPGe / Battery State of Health SoH
For decades, we’ve set the standard in testing and certifying internal combustion engines. Now, we’re driving the future of mobility by doing the same in electrification. With our NEW state-of-the-art 30,000 sq. ft. chassis dynamometer facility launching in Q2 2026, we’ll certify EV efficiency •MPGe and •Battery State of Health (SoH) to ensure performance, reliability, and compliance for next-generation electric vehicles.