16 - ENVIRONMENTAL AND ELECTRICAL TESTING OF LITHIUM BATTERIES

7 + 7 battery test variants

Comprehensive Lithium Battery Validation

Our battery testing facility handles cells and modules up to 800 x 800 x 400 mm (30 kWh capacity, 150 kg) through comprehensive environmental and electrical testing. Environmental tests include vibration with climatic cycling (-40 °C to 75 °C), corrosion, IP protection, and mechanical loading including nail penetration and crush tests. Electrical validation covers overcharging, deep discharging, short circuit simulation, thermal runaway, and performance cycling using powerful cyclers (module testing up to 80 V/1800 A/60 kW and cell testing with 36 channels at 6 V/250 A).

Advanced Testing Infrastructure & Safety

Our specialized testing equipment includes dedicated battery climatic chambers (1 m³, 150 kg load capacity), shock chambers, and vibration systems with integrated climate control (22 - 60kN). Testing is supported by liquid cooling chillers (-30 °C to 90 °C, 53 kW) and comprehensive data acquisition systems from Dewesoft and National Instruments. All testing incorporates advanced safety protection with CAN/LIN communication for BMS monitoring, specialized climate-controlled secure sample storage, and adaptability for special customer requirements including custom LabView configurations.

SCOPE

Test samples: battery cells and modules up to 800 × 800 × 400 mm size; 30 kWh capacity; 150 kg weight

Environmental tests

Vibration + climatic loading
Climatic loading -40 °C – 75 °C
Corrosion
IP protection
Mechanical loading
Nail penetration
Static and dynamic crush

Electrical tests

Overcharging
Deep discharging
Overheating
Short circuit tests
Thermal runaway tests (overcharge and overheat)
Performance and endurance tests
Complete service with cycling and monitoring features

EQUIPMENT

Electrical Cyclers for module level testing: channel (bi-directional) 0,1 V – 80 V / 450 A, 15 kW; 12 channels fully modular (parallel channels configuration); max. 80 V / 1800 A, 60 kW per channel, 0,1 V – 300 V / 225 A, 4 × 18 kW; 4 channels fully
Electrical Cyclers for cell level testing: 16 channels, 10 V / 250 A, extendable to 36 channels
Climatic chambers dedicated for battery testing: 1 m3 volume, max. 150 kg per load (higher hazard level)
Temperature shock chambers: volume 120 l and 672 l, max. 50 kg per shelf
Vibration systems with climatic chambers: 22 kN – 60 kN; 1 m3 – 12 m3
Chillers for liquid cooling: -30 °C – +90 °C; 53 kW

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