{"id":16712,"date":"2026-09-03T09:30:00","date_gmt":"2026-09-03T07:30:00","guid":{"rendered":"https:\/\/tps-elektronik.com\/?p=16712"},"modified":"2026-08-26T07:57:46","modified_gmt":"2026-08-26T05:57:46","slug":"bidirectional-dc-dc-modules-in-lithium-ion-cell-formation-enabling-energy-recycling-and-precise-current-control","status":"publish","type":"post","link":"https:\/\/tps-elektronik.com\/en\/bidirectional-dc-dc-modules-in-lithium-ion-cell-formation-enabling-energy-recycling-and-precise-current-control\/","title":{"rendered":"Bidirectional DC-DC Modules in Lithium-Ion Cell Formation: Enabling Energy Recycling and Precise Current Control"},"content":{"rendered":"\n<p class=\"wp-block-paragraph\">In the lithium\u2011ion battery manufacturing chain, the lithium cell formation system and the aging process consume a large share of total energy. Traditional discharge methods waste stored energy as heat. This drives up operational costs and adds extra load on facility cooling. A battery testing power supply built around a bidirectional isolated converter changes this. Instead of wasting energy, the converter returns it to the grid or reuses it in the system. Our design team has developed a <a href=\"https:\/\/www.shop-tps.com\/shop\/category\/power-modules-179\" data-type=\"link\" data-id=\"https:\/\/www.shop-tps.com\/shop\/category\/power-modules-179\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">high efficiency bidirectional module<\/a> for energy recycling aging systems. It achieves over 93% round\u2011trip efficiency. It also maintains \u00b10.05% current accuracy. The module includes CAN bus communication, integrated protection, and a compact rear\u2011inlet front\u2011outlet airflow design. It meets the rigorous demands of modern battery production lines.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">This article explains how bidirectional DC\u2011DC technology transforms cell formation and aging. It covers key design considerations for battery testing applications. It also presents measurable benefits from real\u2011world deployment. You may design a lithium cell formation system or upgrade an existing energy recycling aging system. Understanding the power stage is critical for quality and energy efficiency.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">The Role of Power Conversion in Lithium Cell Formation and Aging<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Cell formation is the first charge\u2011discharge cycle of a newly assembled lithium\u2011ion cell. During this cycle, the solid electrolyte interphase (SEI) layer forms. The process requires precise current and voltage control. This ensures uniform SEI growth and long\u2011term cell reliability. A dedicated battery testing power supply must deliver stable current at very low voltages. These voltages sometimes fall below 2.5 V. The supply must also maintain low ripple and fast transient response.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Aging involves repeated charge\u2011discharge cycles over days or weeks. It identifies defective cells and stabilizes capacity. In a conventional energy recycling aging system, resistive loads dissipate discharge energy as heat. This wastes energy and creates thermal challenges. A bidirectional isolated converter replaces the passive load. The same hardware then operates in two quadrants. It sources current during charge and sinks current during discharge. It returns energy to a common DC bus or back to the AC grid through a front\u2011end inverter.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Our design team has made this transition seamless. The module implements bidirectional power flow with synchronous rectification on both sides. The high\u2011voltage side and the low\u2011voltage side both use this method. This eliminates diode forward drops. It also enables true four\u2011quadrant operation. The same unit can handle both charging and discharging. No hardware reconfiguration is required.<\/p>\n\n\n\n<figure class=\"wp-block-image size-full\"><img decoding=\"async\" width=\"1717\" height=\"916\" src=\"https:\/\/tps-elektronik.com\/wp-content\/uploads\/2026\/08\/2.jpg\" alt=\"Block diagram of an energy recycling aging system using bidirectional DC-DC modules, showing multiple battery channels connected to a common DC bus and a grid-tied inverter.\" class=\"wp-image-17099\"\/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\">Key Features of a Bidirectional DC-DC Module for Battery Testing<\/h2>\n\n\n\n<ul class=\"wp-block-list\">\n<li><strong>High Efficiency Bidirectional Module<\/strong> \u2013 Reaches 96.5% peak efficiency and over 93% round\u2011trip efficiency at rated power. This reduces energy costs and heat in high\u2011density cabinets.<\/li>\n\n\n\n<li><strong>Bidirectional Isolated Converter<\/strong> \u2013 Provides galvanic isolation between the battery side and the DC bus. This enhances safety and allows floating battery channels.<\/li>\n\n\n\n<li><strong>Wide Voltage and Current Range<\/strong> \u2013 Supports battery voltages from 0 V to 5 V. It handles currents up to 100 A per channel. This suits various cell chemistries and capacities.<\/li>\n\n\n\n<li><strong>CAN Bus Communication<\/strong> \u2013 Uses an integrated CAN 2.0B interface with a standard protocol. It allows real\u2011time monitoring, parameter setting, and fault reporting. Large\u2011scale system integration needs minimal engineering effort.<\/li>\n\n\n\n<li><strong>Rear\u2011Inlet Front\u2011Outlet Airflow<\/strong> \u2013 Designed for rack\u2011mount installation. The forced air cooling path aligns with typical cabinet airflow. This prevents hot air recirculation and reduces internal temperature rise.<\/li>\n\n\n\n<li><strong>Intelligent Fan Control<\/strong> \u2013 Adjusts fan speed automatically based on internal temperature and load. This minimizes noise during low\u2011power operation and extends fan life.<\/li>\n\n\n\n<li><strong>Comprehensive Protection<\/strong> \u2013 Includes over\u2011voltage, over\u2011current, over\u2011temperature, and reverse\u2011polarity protection. Safe operation continues even under abnormal conditions.<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">These features are not just specifications. They result from iterative design refinements. We based them on feedback from battery testing equipment manufacturers and end users. Our team has validated each parameter through extensive testing in real formation and aging lines.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">How Energy Recycling Works in a Formation System<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">A multi\u2011channel formation system processes hundreds or thousands of cells at once. Each channel needs its own power stage. It must charge and discharge. A bidirectional isolated converter module handles one or several channels. This depends on the power rating. During charging, the converter draws energy from the DC bus. It delivers a precisely controlled current to the cell. During discharging, the converter reverses its power flow. It boosts the cell\u2019s low voltage to the DC bus level. Then it feeds energy back into the system.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The discharged energy is not lost. The DC bus is shared among all channels. Discharging cells supply energy to the bus. Other charging channels use that energy at the same time. Surplus energy can be inverted back to the AC grid. This further improves plant efficiency. Our module\u2019s high efficiency design keeps conversion losses low during energy transfer.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Design Considerations for Battery Testing Power Supplies<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Designing a power supply for lithium cell formation differs from designing a general\u2011purpose DC source. Pay special attention to these aspects:<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Low\u2011Voltage Operation<\/strong> \u2013 Lithium cells operate from about 2.5 V to 4.2 V. A buck\u2011derived topology must handle duty cycles near 0% during low\u2011voltage charging. Our module uses a synchronous buck\u2011boost or isolated full\u2011bridge topology. It maintains stable operation down to 0 V output. This is essential for initial formation when cell voltage is near zero.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Current Accuracy and Ripple<\/strong> \u2013 The SEI formation process is sensitive to current ripple. Excessive ripple can cause non\u2011uniform lithium plating. It shortens cell lifetime. Our battery testing power supply achieves current ripple below 0.1% RMS. Current setpoint accuracy is \u00b10.05% full scale. A high\u2011bandwidth current loop and interleaved power stages make this possible.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Thermal Management in Dense Cabinets<\/strong> \u2013 Formation systems often pack many channels into one rack. The rear\u2011inlet front\u2011outlet airflow of our module aligns with the cabinet\u2019s natural cooling path. This prevents hot spots and allows higher channel density. The intelligent fan control reduces noise during low\u2011load operation. It also ensures reliable operation up to 50\u00b0C ambient temperature.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Communication and Synchronization<\/strong> \u2013 In a 512\u2011channel system, the host controller must communicate with every power module. CAN bus communication is the preferred interface. It offers robustness and multi\u2011master capability. Our module supports 11\u2011bit and 29\u2011bit identifiers. Baud rates are configurable up to 1 Mbps. The command set covers voltage\/current setting, status readback, and fault flagging.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Case Study: Energy Recycling in a 512\u2011Channel Aging System<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Our team ran a field test in a 512\u2011channel energy recycling aging system for 18650 cells. Each channel handled 10 A charge\/discharge. We divided the system into 64 groups. Each group used one bidirectional DC\u2011DC module with eight channels per module. The modules connected to a common 48 V DC bus. A regenerative inverter tied the bus to the AC grid.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">During discharge, the modules returned energy to the DC bus. The average efficiency was 92.8%. The regenerative inverter fed the surplus back to the grid. Over 30 days, the system saved 35% energy compared to a resistive\u2011load aging system. The precise current control also reduced cell rejection rates by 0.4%. This directly improved yield.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Protection and Reliability Requirements<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">A reliable bidirectional converter in battery manufacturing must withstand continuous operation. It must handle frequent power cycling and occasional abnormal events. Our module includes multiple layers of protection. Hardware\u2011based fast over\u2011current shutdown and software\u2011based over\u2011voltage and over\u2011temperature limits work together. The protection function power module also adds input reverse\u2011polarity protection and output short\u2011circuit protection. A single channel failure does not affect the whole system.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Reliability improves with conservative component derating and a robust thermal design. The forced air cooling system uses high\u2011quality ball\u2011bearing fans. They last 70,000 hours at 40\u00b0C. The rear\u2011inlet front\u2011outlet airflow keeps dust away from critical components. Positive pressure inside the module supports this.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Compliance and Global Standards<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Battery testing equipment operates worldwide. Power modules must meet international safety and EMC standards. Our module complies with UL standards power module (<a href=\"https:\/\/www.shopulstandards.com\/ProductDetail.aspx?productId=UL62368-1\" data-type=\"link\" data-id=\"https:\/\/www.shopulstandards.com\/ProductDetail.aspx?productId=UL62368-1\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">UL 62368\u20111<\/a>), CE standards power module (<a href=\"https:\/\/webstore.iec.ch\/en\/publication\/69308\" data-type=\"link\" data-id=\"https:\/\/webstore.iec.ch\/en\/publication\/69308\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">IEC\/EN 62368\u20111<\/a>), and CCC standards power module (<a href=\"https:\/\/openstd.samr.gov.cn\/bzgk\/std\/newGbInfo?hcno=862145EBF14F5CC3771FC64CE94A48DF\" data-type=\"link\" data-id=\"https:\/\/openstd.samr.gov.cn\/bzgk\/std\/newGbInfo?hcno=862145EBF14F5CC3771FC64CE94A48DF\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">GB 4943.1<\/a>). These cover North America, Europe, and China. For electromagnetic compatibility, the module meets <a href=\"https:\/\/img.antpedia.com\/standard\/files\/pdfs_ora\/20211002\/EN%2055032-2015-A1-2020.pdf\" data-type=\"link\" data-id=\"https:\/\/img.antpedia.com\/standard\/files\/pdfs_ora\/20211002\/EN%2055032-2015-A1-2020.pdf\" target=\"_blank\" rel=\"noopener noreferrer nofollow\">EMC compliant EN55032<\/a> Class B limits. This applies to conducted and radiated emissions. Pre\u2011compliance testing shows at least 6 dB margin.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">These certifications reflect a design philosophy that prioritizes safety, electromagnetic hygiene, and long\u2011term reliability. Our team has invested in pre\u2011compliance testing and certification support. This reduces the burden on customers when they bring systems to market.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\">Conclusion and Key Parameters<\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Bidirectional isolated converters are now essential in lithium cell formation and aging systems. They enable bidirectional energy flow and energy recycling. This reduces operational costs and improves cell quality. Our design team has delivered a high efficiency bidirectional module. It combines precise current control, robust communication, and global compliance. It is ready for the next generation of battery testing equipment.<\/p>\n\n\n<style id=\"wpforms-css-vars-4659-block-82121049-122a-48c7-8acb-0e0be4e5d338\">\n\t\t\t\t#wpforms-4659.wpforms-block-82121049-122a-48c7-8acb-0e0be4e5d338 {\n\t\t\t\t--wpforms-field-size-input-height: 43px;\n--wpforms-field-size-input-spacing: 15px;\n--wpforms-field-size-font-size: 16px;\n--wpforms-field-size-line-height: 19px;\n--wpforms-field-size-padding-h: 14px;\n--wpforms-field-size-checkbox-size: 16px;\n--wpforms-field-size-sublabel-spacing: 5px;\n--wpforms-field-size-icon-size: 1;\n--wpforms-label-size-font-size: 16px;\n--wpforms-label-size-line-height: 19px;\n--wpforms-label-size-sublabel-font-size: 14px;\n--wpforms-label-size-sublabel-line-height: 17px;\n--wpforms-button-size-font-size: 17px;\n--wpforms-button-size-height: 41px;\n--wpforms-button-size-padding-h: 15px;\n--wpforms-button-size-margin-top: 10px;\n\t\t\t}\n\t\t\t<\/style><div class=\"wpforms-container wpforms-container-full wpforms-block 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-->","protected":false},"excerpt":{"rendered":"<p>In the lithium\u2011ion battery manufacturing chain, the lithium cell formation system and the aging process consume a large share of total energy. Traditional discharge methods waste stored energy as heat. This drives up operational costs and adds extra load on facility cooling. A battery testing power supply built around a bidirectional isolated converter changes this.\u2026 <a href=\"https:\/\/tps-elektronik.com\/en\/bidirectional-dc-dc-modules-in-lithium-ion-cell-formation-enabling-energy-recycling-and-precise-current-control\/\">Read More &raquo;<\/a><\/p>\n","protected":false},"author":7,"featured_media":17079,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"footnotes":""},"categories":[53],"tags":[],"class_list":["post-16712","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-production"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Bidirectional DC-DC Modules in Lithium-Ion Cell Formation: Enabling Energy Recycling and Precise Current Control - TPS<\/title>\n<meta name=\"description\" content=\"Discover how a bidirectional DC-DC module enables energy recycling in lithium cell formation and battery testing systems.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/tps-elektronik.com\/en\/bidirectional-dc-dc-modules-in-lithium-ion-cell-formation-enabling-energy-recycling-and-precise-current-control\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Bidirectional DC-DC Modules in Lithium-Ion Cell Formation: Enabling Energy Recycling and Precise Current Control - 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