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Electric vehicle battery testing

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See more:

  • Vibration testing
  • Thermal shocks – air
  • Testing internal and external corrosion/erosion of heat exchangers
  • Tests of products’ resistance to corrosion
  • Testing electric and hybrid vehicles
  • Battery testing
  • Electric vehicles – system integration, diagnostics and testing
  • BOSMAL for electromobility

The traction battery is currently one of the most expensive – if not the most expensive – components of an electric vehicle. It is also a component which can cause a lot of problems for designers and users of these vehicles.
The batteries used to power electric vehicles, as well as the materials they are produced from, must meet the demands of a number of standards, as well as other requirements.

Expectations for battery performance:

  • high performance and reliability
  • long battery lifetime (long-term failure-free operation without any noticeable changes in terms of deteriorating performance characteristics),
  • high efficiency and power (the highest possible energy density and power output, which enable driving the longest possible distance following the shortest possible charging time),,
  • operational safety,
  • low environmental impact,
  • wide range of operating temperatures (from -30 to 65ºC),
  • easy monitoring of operating parameters,
  • maintenance-free operation,
  • low price (low production and operating costs),

Unfortunately, those are features which are very often difficult to reconcile with one another.
Functioning of an electric vehicle is greatly influenced by ambient temperature. For this reason, the system for cooling (and possibly heating) batteries is of great importance. The system can be either active – using liquid or air – or passive, transmitting heat through the battery housing. By lowering the cell temperature, the charging speed can be kept at a high level for longer. Heating (when necessary) protects the cells from freezing and the resulting temporary drop in capacity.
With its extensive research facilities and specialized staff, BOSMAL performs a number of tests on electric vehicles, including tests of their batteries and cooling systems (more specifically: TMS – thermal management systems).

Selected research and testing carried out at BOSMAL

Various types of battery testing are performed at BOSMAL. These include:

  • tests of electrical parameters and characteristics,
  • tests of resistance to environmental conditions,
  • battery charging/discharging cycles

Thermal and climatic testing

Thermal and/or climatic tests (tests of battery resistance to environmental conditions) are superimposed with charging and discharging cycles.

Vibration testing

Vibration tests with parameters monitoring, coolant circulation, loading/charging.

IP testing

Water and/or dust resistance testing, so-called IP tests (IP6K9K, IP6K6, etc.).

Battery charging/discharging cycles

Battery charging and discharging tests.

Battery charging system

Regenerative Power System

Power supply parameters

  • Output Voltage: from 0 to 800 V
  • Output Current: from -300 to 300 A
  • Output Power: from -90 to 90 kW
  • Rise time/Fall time: ≤30 ms

Load parameters

  • Output Voltage: from 0 to 800 V
  • Output Current: from 0 to 300 A
  • Output Power: from -90 to 90 kW
  • Rise speed rate/Fall speed rate: 300 A/ms

Measurements of electrical parameters and characteristics

BOSMAL performs measurements of electrical parameters (power, current, resistance) of various types of electrical and electronic vehicle components, including batteries.

Mechanical tests

Mechanical integrity – UNECE Regulation No. 100 Annex 9D

The purpose of this test is to check the safety of the REESS (rechargeable energy storage system) when subjected to contact stresses that might occur during a vehicle collision.

Mechanical shocks of car batteries according to Annex 9C of UNECE Regulation No. 100

Tests of vehicle batteries – REESS (rechargeable energy storage systems).
Testing of automotive batteries at inertial loads that might occur during a vehicle collision.

Flammability

Selected norms

  • ISO 16750-1,
  • ISO 16750-2,
  • ISO 16750-3,
  • ISO 16750-4,
  • IEC 60068-2-1,
  • IEC 60068-2-2,
  • IEC 60068-2-64,
  • IEC 60068-2-6,
  • IEC 60068-2-27,
  • ISO 20653,
  • IEC 60068-2-30,
  • IEC 60068-2-64.

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