Batterie-Tests

Battery Testing

In the development of batteries and battery management systems for electric vehicles (EVs), extensive testing and validation play a critical role. These tests help determine the load limits of battery cells, modules, and complete battery packs. They encompass lifetime tests conducted within climate chambers, as well as power tests involving charge and discharge cycles that span several weeks. Throughout these tests, continuous monitoring of cell voltage and temperature is essential for each battery cell. In addition, a range of evaluations, including crash tests, battery drop tests, penetration tests, compression, bending, vibration tests, battery abuse testing, and exposure to varying temperatures and stresses, are conducted. Data from third-party devices are collected through the battery cell tester system and undergo automatic evaluation.

 

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Typical Test Methods:

Testing lithium-ion batteries for electric vehicles involves several methods for assessing performance, capacity, and overall health. These methods include: 

 

Capacity Testing:

This test assesses a battery's charge storage capacity by fully charging it and then discharging it at a controlled rate while measuring time and voltage drop. It provides insights into available capacity and monitors degradation over time.

 

State of Charge (SOC) Testing:

SOC testing measures the battery's current charge level by monitoring voltage, current, and temperature. Mathematical models are used to estimate SOC, a crucial parameter for determining remaining range and optimizing battery usage.

 

State of Health (SOH) Testing:

SOH testing evaluates a battery's overall health and performance by analysing various parameters, including capacity, internal resistance, voltage response, and impedance spectroscopy. These tests identify degradation, aging, or performance loss in the battery.

 

Cycle Life Testing:

This test assesses a battery's durability and longevity by subjecting it to repeated charge and discharge cycles. It helps determine the number of cycles a battery can endure before significant capacity degradation occurs.

 

Thermal Testing:

Thermal testing assesses a battery's performance and safety under different temperature conditions, monitoring temperature rise, cooling efficiency, and the risk of thermal runaway.

 

Safety Testing:

Safety testing evaluates how a battery responds to abnormal conditions such as overcharging, over-discharging, short circuits, and mechanical abuse. It includes tests like crush, puncture, and nail penetration tests to assess the battery's ability to withstand accidents and prevent thermal runaway.

 

Fast Charging Testing:

This test evaluates a battery's ability to handle high-power charging, assessing parameters like temperature rise, voltage response, and capacity retention. It ensures compatibility with fast-charging infrastructure.

 

Battery pack testing for electric vehicles requires specialized equipment for measurement and control, which includes devices like thermal chambers and bidirectional DC sources. Adherence to battery testing standards and safety guidelines is crucial to ensure accurate results and minimize risks during testing.

 

Highly Insulated and Safe

Measuring points in the high-voltage range are hazardous areas. To ensure personal and occupational safety, various measures must be taken to minimise property damage and personal injury or to exclude liability issues in the event of a fault. On the one hand, only highly insulated measuring modules may be used, on the other hand, the installation and wiring of the measuring modules may only be carried out by trained or qualified personnel.

 

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