Testing safely in high-voltage environments

Automated testing and evaluation of e-vehicle batteries

高电压环境下的安全测试

电动汽车电池的自动测试和评估

在为电动汽车开发新电池和电池管理系统时，广泛的测试和验证是当务之急。这包括生命周期测试和误用测试。这些可用于确定电池芯、电池模块和完整电池组的负载极限。调查包括气候室中的充电和放电循环以及碰撞载荷、穿透、压缩、弯曲和振动试验。这些全面的测试需要一个灵活、自动化的测试系统，包括数据评估。测量技术在高压环境中安全、无干扰地获取数据。SK Innovation是世界上最大的电池制造商之一，它依靠imc Test&measurement的高压测量技术，并委托多个测量架进行电池测试。

 

Endurance test with the imc test rack

The 19”-test rack captures all measured values on a battery module consisting of several individual battery cells. Cell voltage and temperature are measured and monitored during the test on each bat-tery cell. For this, SK Innovation uses several 19” racks. The test system also acquires the voltage of the battery modules and the entire battery pack. imc STUDIO software also controls and regulates the bidirectional DC source for the charging and dis-charging process and monitors measurement quantities

Schematic structure of the measuring rack
Schematic structure of the measuring rack. The imc CRONOSflex measuring system measures, controls and regulates.

Life cycle and destruction tests

The various battery tests are used to deter-mine the life cycle and reliability of the e-vehi-cle battery in different load situations, such as simulating an accident. Tests with crash, pene-tration, compression, and bending loads serve to provide information about the safety of a battery pack and are stipulated by standards. Lithium-ion batteries require the correct test environment for the tests specified here, as the targeted destruction of the battery system leads to the dreaded “thermal runaway”. The melting of the separator leads to an un-controlled release of the stored energy of the cells. The oxygen content in the environment can lead to a fire or an explosion of the battery cells. The test environment must be designed to be fire-proof and explosion-proof, or pressure waves must be diverted in a tar-geted manner and the pollutants produced may only be filtered into the atmosphere.

Penetration Load Test

When testing penetration load, the imc test system records the battery cell voltage. The temperature is recorded with a thermal imag-ing camera. A film camera documents 5 destruction. All images and measurement data are stored synchronously for evaluation.

Misuse- and crash-Test

A thermal imaging camera and a high-speed camera are used for dedicated mechanical de-formation tests on the battery pack (crash, compression, and bending loads). Here, too, the measurement data and camera images are stored synchronously.

Vibration-test

In the vibration test, the batteries are sub-jected to oscillations that occur during vehicle operation to analyze material loads on the sys-tem. A so-called “shaker” generates strong vi-brations, while the test system monitors the condition of the battery pack during charging and discharging.

Life cycle test in a climatic chamber

The life cycle test of a battery pack includes charging and discharging cycles over several weeks to test the performance of a battery. The battery pack is exposed to various de-grees of humidity and temperature profiles in a climatic chamber

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