18 - BATTERY ABUSE TESTING

We have developed a special container with a length of 6 m

Extreme Battery Failure Mode Testing

Our battery abuse testing facility evaluates cells, modules, and small packs under extreme conditions including overcharging (1500 V/1850 A/75 kW), exhaustive discharge, overheating, freezing, nail penetration, crushing (250 kN), freefall, and short circuit testing (up to 15kA). Tests are conducted in a specialized 6 x 2.5 x 2.5 m container with 5mm steel walls, temperature control, and comprehensive safety systems including triple-redundant fire suppression, 7 m³ emergency flooding, and gas detection with ventilation.

Maximum Safety & Monitoring Infrastructure

Our facility incorporates advanced safety features including separate control rooms, flue gas filtration, contaminated water collection, and comprehensive surveillance systems with thermal imaging. Data acquisition covers 60 channels monitoring temperature, pressure, voltage, and current using Dewesoft and National Instruments systems with CAN/LIN BMS communication. All testing complies with UN38.3, ČSN 62619, ECE R100, and Volkswagen standards, with climate-controlled secure storage for test samples and support for specialized customer requirements.

SCOPE

Test samples: battery cells, modules, small packs
Overcharging up to 1500 V or 1850 A (~75 kW)
Exhausting discharge
Overheating with a heating element
Freezing
Nail penetration
Crushing up to ~250 kN
Freefall
Short circuit – current to 15 kA, cell and module level
Special hazardous tests
Long-term tests (duration in days to weeks)

EQUIPMENT

Dedicated test container: 6 m × 2,5 m × 2,5 m internal space; 5 mm thickness steel walls; fully openable in 6 m length; tempered climate
Control safety room with complete overview of all measured values
Fire extinguishing system – three independent circuits for unexpected situations
Flue gas filtration and contaminated water collection
Emergency flooding – 7 m³ of extinguishing water
Camera system for surveillance – optional high-speed camera and thermal camera
DAQ up to 60 channels (thermocouples, pressure measurement, voltage/current)
Flammable gas detection (first ventilation)

BENEFITS

DAQ systems Dewesoft, National Instruments, Lab View
CAN/LIN communication with BMS
Safety protection system
Support of special customer requirements (e.g. LabView controlling or different setup)
Battery test samples storage clima-controlled and secures container

STANDARDS