Case Study: Leading E‑Bike and Cell and Battery Manufacturer achieves 60% smaller manufacturing footprint and 30% energy savings with Keysight BT2200 cell‑formation solution

Powering E-Bikes and Battery Energy Storage Systems with Cell-Formation Solution

Leading E-Bike and Cell and Battery Manufacturer faced a production ramp-up challenge as e-bike orders grew and safety/performance standards tightened. Their legacy cell-formation system was hard to configure, lacked onsite support after the previous supplier exited the market, and needed to work with existing pouch cell fixtures. Keysight was selected to address these urgent scalability, configurability, and support needs using its BT2200 charge-discharge platform (BT2202A chassis and BT2204B modules).

Keysight implemented the compact BT2200 solution, enabling reuse of existing fixtures, flexible multi-test configuration, and high-capacity scalability. The result: a 60% reduction in manufacturing footprint, a 30% reduction in net energy consumption through AC power regeneration back to the grid, and easier early removal of defective cells—freeing floor space and lowering operating and cooling costs while meeting production and safety requirements.