Voltavision presents new generation of the ES-300 rack-in system for pouch cell contacting.

The Voltavision ES-300 represents a new generation of rack-in systems for testing pouch cells in test environments. Specifically designed to meet the requirements of state-of-the-art battery development and cell testing, the systematically enhanced solution offers greater flexibility for contacting different cell formats, more test positions per test chamber, reduced material usage, and lower weight. Test specimens can be prepared outside the chamber and then inserted quickly and easily as a complete rack-in unit, while integrated voltage measurement at the contact element enables more precise voltage measurement and reduced contact resistance, even at high currents.

Faster setup and reproducible test procedures

The ES-300 system consists of a rack-in unit (E-300) and the corresponding rack (EG-300). The test specimen is positioned on the rack-in unit outside the test or climatic chamber and fully prepared there. The complete rack-in unit is then inserted into the rack, automatically establishing the electrical contact. Guide rails provide mechanical guidance, while a visual alignment aid ensures that the rack-in unit is correctly inserted and fully engaged. This tool-free plug-in principle significantly reduces setup times while ensuring stable and reproducible test conditions.

High current-carrying capacity and precise measurement for different cell geometries

A key feature of the new ES-300 generation is its significantly increased flexibility when contacting cell tabs. The contact elements are not fixed in position but can be variably positioned along defined axes. This allows different cell formats and tab positions to be accommodated, for example with contacts arranged on one side or on opposite sides. The system is therefore suitable for a wide range of pouch cell formats and, with the appropriate adapters, can also accommodate cylindrical cells. Customer-specific adaptations are also possible. The usable area of the rack-in unit for cell positioning is typically 400 × 240 mm, including the contact elements.

The current-carrying capacity of the ES-300 is configured according to the specific project and supports high-current applications of up to 300 A. This makes the system suitable for realistic testing under representative load conditions in development and validation. In addition, the system features integrated voltage measurement directly at the contact element. The measurement points are located in close proximity to the cell terminals, helping to reduce contact resistance and improve measurement quality. Electrical connections are provided via an integrated connector panel, which can be equipped with different interfaces depending on the application requirements.

The permissible operating voltage is 6 V DC, while additional electrical parameters are defined according to the specific application. The ES-300 operates reliably across a broad temperature range from -40 °C to +80 °C and at a relative humidity of 0 to 75%, making it suitable for modern battery testing under demanding environmental conditions.

Material-optimized design and more efficient use of chamber space

Thanks to its redesigned construction and the horizontal arrangement of the test specimens, Voltavision’s proprietary ES-300 system enables more efficient use of the available space inside test chambers. In typical applications, several rack-in units can be operated in parallel, significantly increasing the number of possible test channels. This provides a particular advantage where chamber space is limited and supports more economical use of existing testing capacity.

The system has also undergone substantial structural optimization. Previously material-intensive components have been reduced to the technically necessary minimum and are manufactured using modern production methods such as 3D printing. This significantly reduces both material consumption and manufacturing waste. The result is a lighter, more resource-efficient design while maintaining a high level of functionality. Users benefit from improved handling in day-to-day laboratory operations as well as a more efficient and sustainable overall system design. The rack-in unit itself weighs approximately 2.4 kg and measures 485 × 355 × 60 mm.

With its flexible configuration and high performance, the new generation of the proprietary ES-300 is designed for use in demanding testing and development environments. The system is already in use at Voltavision’s own facilities and is also available to external test laboratories and industry partners seeking an efficient and reproducible solution for contacting pouch cells.