Battery Holders: A worked example on how good design saves time
- Kelly Martin
- Oct 27
- 2 min read
Setting up a new batch of cells is often time-consuming and fiddly, which is why we wanted to test out how much time our Battery Holder System really saves.
Kelly Martin, Communications Manager
We all know that setting up a new batch of cells for testing takes time. Once you've finalised your test plan - cell count, temperatures, parameters - you’re faced with the challenge of physically connecting to the cells. That often means fiddly work: bolting, welding, all while trying to maintain reliable contact. Then comes threading wires into the thermal chamber, positioning everything, and then finally, testing.
But what if you need to make changes mid-test? Swapping cells frequently or adjusting compression plates can drastically increase setup time and complexity. Cognition Energy’s Battery Holder System makes cell testing faster, more reliable, and safer. Designed with efficiency in mind, it features quick-change cards that require no wiring, streamlining setup and minimising downtime.
Our worked example
To prove our point, we recently timed an engineer working on a client project using one of our Battery Holder Systems: a rack of 15 pouch cell holders inside an MK115 thermal chamber. The project required 3 to 4 compression adjustments on all 15 cells per week, a complex and repetitive task.
So was using the Battery Holder System more efficient?
Yes! We timed our engineer and removing and replacing a cell holder in the Battery Holder System took just 20 seconds, compared to 3 minutes 54 seconds with a traditional setup. With 15 cells, that’s a 53-minute time saving per adjustment.
Standard Pouch Holders | Quick-Change Pouch cards | |
Time taken to remove & replace in thermal chamber | 0:03:54 | 0:00:20 |
Number of holders to be removed & replaced | 15 | 15 |
Total time taken | 0:58:30 | 0:05:00 |
We multiplied this up for the duration of the 4 month project and in total we saved ourselves approximately 56.2 hours on just the removal and installation of the cards over the project!
Would you be interested in more details on the Battery Holder System? Contact us now!