The battery’s performance and reliability are critical to ensure the quality of the whole electric vehicle. So, Electric vehicle (EV) battery testing is more important than ever as manufacturers embrace alternative power sources.
The environmental test including vibration and shock testing under different climatic conditions (temperature, humidity)，dust and salt fog testing, altitude simulation, IPXX, immersion splash water testing.
LIB Industry can help you to perform these testing.
Temperature Test
Test Standard: IEC 62660-2
1. Thermal Test
This test is performed to characterize cell responses to high-temperature environment.
a) Adjust the SOC of the cell to 100% for BEV application, and to 80% for HEV application.
b) The cell, stabilized at room temperature, shall be placed in a gravity or circulating air-convection oven. The oven temperature shall be raised at a rate of 5K/min to a temperature of 130℃±2K. The cell shall remain at this temperature for 30 min before the test is discontinued.
Note-If necessary, to prevent deformation, the cell may be maintained during the test in a manner that does not violate the test purpose. The manner to prevent deformation should be representative of cells inside battery systems and battery packs.
2. Temperature cycling
This test is performed to characterize thermal durability of a cell by exposing at a low and high temperature environment alternately to cause expansion and contraction of cell components.
a) Adjust the SOC of the cell to 100% for BEV application, and to 80% for HEV application.
b) Perform the temperature cycling in accordance with ISO 16750-4 as shown in Table 4 the minimum operating temperature shall be -40℃ or Tmin specified by the cell manufacturer and the maximum operating temperature shall be 85℃ or Tmax specified by the cell manufacturer. Perform 30 test cycles as specified.
Cumulative time min | Temperature ℃ |
0 | 25 |
60 | Tmin |
150 | Tmin |
210 | 25 |
300 | Tmax |
410 | Tmax |
480 | 25 |
Test Standard: UL1642-2015 Clause 17
A battery is to be heated in a gravity convection or circulating air oven with an initial temperature of 20±5℃(68±9℉). The temperature of the oven is to be raised at a rate of 5±2℃(9±3.6℉) per minute to a temperature of 130±2℃ (266±3.6℉)and remain for 10 min. The sample shall return to room temperature (20±5℃) and then be examined. For batteries specified for temperatures above 100℃(212℉), the conditioning temperature shall be increased from 130±2℃(266±3.6℉), to 30±2℃(86±3.6℉) above the manufacturers maximum specified temperature. For a battery of lithium metal chemistry, the conditioning temperature shall be increased to a maximum of 170±2℃(338±3.6℉).
Test Standard: UL 1642-2015 Clause 18
1. Temperature cycling test
a) Raising the chamber-temperature to 70±3℃(158±5℉) within 30 min and maintaining this temperature for 4h.
b) Reducing the chamber temperature to 20±3℃(68±5℉) within 30 min and maintaining this temperature for 2h.
c) Reducing the chamber temperature to -40±3℃(-40±5℉) within 30 min and maintaining this temperature for 4h.
d) Raising the chamber temperature to 20±3℃(68±5℉) within 30 min.
e) Repeating the sequence for a further 9 cycles.
f) After the 10th cycle, storing the batteries for a minimum of 24h, at a temperature of 20±5℃(68±9℉) prior to examination.
2. Test Standard: GB/T 31467.3-2015 Clause 7
A) The test specimen is a battery pack or system
B) Place the test specimen in an alternating temperature environment of (-40±2°C) ~ (85±2°C), and the conversion time between the two extreme temperatures is within 30 minutes. Keep the test specimen in each extreme temperature environment for 8H, and cycle 5 times. Then observe for 2h at room temperature.
3. Test Standard: LV124
• High/low Temperature storage
Operating mode of DUT | Operating Mode |
Test duration and test temperature | 2 cycles of 24h [consisting of 12h storage at T(min) and 12h storage at T(max)] |
Number of DUTs | As specified in the test sequence plan in the Component Requirement Specification. |
• High/low Temperature storage
Operating mode of DUT | During the parameter test (function test) operating mode II.C, otherwise operating mode II.a |
Test Temperature | The DUTs shall be subjected to the temperature profile. Temperature change of 5℃ for each step. |
Test sequence | The DUT shall be maintained at each temperature step until the specified temperature is attained throughout. This shall be followed by a parameter test (function test) as per section “Parameter test”. |
Number of DUTs | 6 |
• Low Temperature Operation
Operating mode of DUT | Intermitting between 12h operating mode II.a and 12h operating mode II.c |
Test duration | 48h |
Test temperature | T (min) |
Numbers of DUTs | 6 |
Temperature Humidity Test
Test Standard: GB/T 31467.3-2015 Clause 8
A) The test specimen is a battery pack or system.
B) Refer to GB/T 2423.4 executing system DB, variables are shown in Figure 4 the highest temperature is +80℃, cycle 5 times. Observe 2h at room temperature.
Test Standard: GB/T2423.4
24-hour Cycle
The temperature inside chamber should be heated to the appropriate high temperature value specified in the relevant standards, and the high temperature should be reached within 3h±30min. The relative humidity at this stage should be no less than 95%, and the relative humidity in the last 15 minutes should be no less than 90%.
It should be kept within ±2K of the specified high temperature limit until 12h ± 30min from the beginning of the cycle. In the first and last 15 minutes of this stage, the relative humidity should be 90%~100%, (93±3) % should be in the rest of the time.
The temperature can be lowered according to one of the two methods below
Method 1: The temperature should drop to 25℃±3K within 3h~6h. The temperature reaches 25℃±3K within 3h±15min. In the first 15 minutes, the relative humidity should not be less than 90%, and no less than 95% in the rest of the time.
Method 2: The temperature should drop to 25℃±3K within 3h~6h, but there is no additional requirement for the first 1.5h in method 1, and the relative humidity should not be less than 80%.
The temperature should be kept at 25℃±3K, and the relative humidity should not be less than 95%, until the end of a 24-hour cycle.
Test Standard: LV124
1. Damp heat, cyclic
Operating mode of DUT | Operating mode II.a |
Total test duration | 144h |
Test variant | Variant 1 |
Upper test temperature | 55 ℃ |
Number of cycles | 6 |
Number of DUTs | 6 |
2. Damp heat, cyclic (with frost)
Operating mode of DUT | Intermitting between 40min operating mode II.a and 10 min operating mode II.c |
Total test duration | 240h |
Number of cycles | 10 |
Test cycle sequence | The first five cycles shall include a cold subcycle and the remaining cycles shall be carried out without a cold subcycle |
Number of DUTs | 6 |
3. Damp heat, steady state
Severity 1
This test shall be carried out in accordance with DIN EN 60068-2-78 with the following parameters.
Operating mode of DUT | Operating mode II.a |
Test temperature | 40 ℃ |
Humidity | F(rel) = 93% |
Test duration | 21 dys |
Number of DUTs | 6 |
Severity 2
This test shall be carried out in accordance with DIN EN 60068-2-78 with the following parameters:
Operating mode of DUT | Intermitting operation between 47h operating mode II.a and 1h operating mode II.c repeating until end of test duration |
Test duration | As specifirf in the component requirement specification as per section 12.5.1 |
Test temperature | 65 ℃ |
Test humidity | 93% relative humidity |
Number of DUTs | 6 |
Prior to the execution of this service life test, a check shall be condected to ascertain whether the high test acceleration using the test parameters 65℃ and 93%RH. Exceeds the physical limits of the materials used in the components (eg. Hydrolysis of plastics). Where applicable, the contractor and client shall agree to changes in the test temperature and test humidity (eg. To +55℃ and 93%RH) while increasing the test duration as per the Lawson model such that the physical limits of the materials used are not exceeded during the test. The overall severity of the testing shall, however, remain unchanged. The test humidity shall not exceed the level of 93% RH.
[Deviating test sequence for components with reduced performance at high temperatures]
For components with reduced performance (e.g. reduction of backlight of LCD displays at high temperatures staring at T (op, max) (＜65℃) the test shall not - deviating from table 73: Test oarameters K-14 Damp heat, steady state- severity 2 - be carried out at a constant test temperature of 65℃, but with the following parameters (see table 73)
Operating mode of DUT | Intermitting operation as per Figure 33 |
Test duration | As specified in the component requirement specification as per section 12.5.1 (Lawson model). The ramp times between 65℃ and T(op,max) shall not be included in the test duration/ |
Test temperature | The temperature gradient shall be selected such that no condensation occurs at the DUT |
Test humidity | 93% relative humidity |
Interval time T1 | 47h |
Interval time T2 | 1h |
Number of DUTs | 6 |
Salt Fog Test Chamber
Test Standard: IEC 60068-2-52
1. The sample should be subjected to visual inspection, electrical and mechanical inspection in accordance with the relevant regulations before testing.
2. The relevant specifications should expatiate the procedures before cleaning the sample, and should state whether to remove the temporary protective layer.
3. Place the test piece in a salt spray cabinet and keep it for 2 hours under the test conditions of 15~35°C temperature and 5% salt spray concentration.
4. After spraying, move the test specimen into a humidity cabinet with 40℃ and 93% relative humidity rapidly (try to avoid the loss of salt water during moving), and perform humidity storage according to the specified residence time.
5. Repeat steps (3) and (4) of the program according to the specified number of cycles.
6. The relevant specifications should state whether to clean the specimen after the test. If it needs to be cleaned, place the test piece under the faucet for 5 minutes and wash it with distilled water or mineral water. Then shake it with bare hands or use a blower to dehydrate. Dry for 1 hour at a temperature of 55±2℃, and the water used for cleaning should not be higher than 35℃.
7. Place the test specimen under standard atmospheric conditions (approximately 1-2 hours), restore it to its original state. However, visual, electrical and mechanical inspections must be checked out before and after the restoration.
[Test Condition]
Salt spray fog
Salt fog concentration: 5%
Test temperature: 15~35℃
Volume of spray: 1~2ml/h·80dm2
PH: 6.5~7.2 (pH at 20±2℃）
Temperature storage
Relative humidity: 93% (RH)
Test temperature: 40℃
Residence time
severity1：Each cycle performs 2 hours of salt water spray and 7 days of temperature storage, and a totally performed 4 cycles.
severity2：Each cycle performs 2 hours of salt water spray and 20~22 hours, and a totally performed 3 cycles.
Test tolerance
Salt fog concentration: ±1%
Test temperature: ±2℃
Relative humidity: +2, -3%
Test Standard: GB/T 31467.3-2015 Clause11
A) The test specimen is a battery pack or system.
B) According to GB/T2423.18 severity degree 5 performed 4 test cycle。
C) The salt solution adopts sodium chloride (chemically pure, analytically pure) and distilled water or deionization device, and its concentration is (5±0.1)% (mass fraction). The pH value measured is between 6.5 and 7.2 at (20±2)℃.
D) Put the test specimen into the salt spray chamber, spray salt spray for 2h at 15℃~35℃, after spraying, move the test specimen to the damp heat chamber for 20h~22h, the temperature is (40±2)℃, relative Humidity is (93±3)%, form a cycle, repeat this cycle for 3 times, and then store for 3D under test standard atmospheric conditions (temperature is 23±2℃, relative humidity is 45%~55%) to form a cycle. Repeat the test for 4 cycles.
Test Standard: LV124
1. Salt spray test, operating, exterior
This test shall be carried out in accordance with DIN EN 60068-2-11 Ka with the following parameters:
Operating mode of DUT | During spray phase: Intermitting between 1h operating mode II.a and 1h operating mode II.c. During test phase: Operating mode II.a |
Test temperature | 35℃ |
Test cycle | Each test cycle consists of an 8h spray phase and a 4h rest phase |
Number of test cycles | For components in the underbody/engine compartment: 12 cycles For other components: 8 cycles |
Number of DUTs | 6 |
When performing the test, the installation position of the component in the vehicle sjhall be simulated.
2. Salt spray test, operating, exterior
This test shall be carried out in accordance with DIN EN 60068-2-11 Ka with the following parameters:
Operating mode of DUT | During spray phase: Intermitting between 55h operating mode II.a and 5min operating mode II.c During rest phase: Operating mode II.a |
Test temperature | 35 ℃ |
Test cycle | Each test cycle consists of an 8h spray phase and a 4h rest phase |
Number of test cycles | 2 |
Number of DUTs | 6 |
When performing the test, the installation position of the component in the vehicle shall be simulated. The test setup (installation position, covers, trim, situation during operation) shall be recommended by the contractor, coordinated with the client and documented.
Sea Water Immersion Test
Test Standard: GB/T 31467.3-2015
A) The test specimen is a battery pack or system.
B) At room temperature, the test specimen is connected to the wiring harness of the whole vehicle in the actual vehicle assembly state, and then placed in the 3.5% NACL solution (mass fraction, seawater composition at room temperature) for 2h in the actual vehicle assembly direction. The water must be deep enough to submerge the test specimen.
Thermal shock Immersion Test
Test Method: LV124
Heat chamber：ambient~+150℃, the general test requirement is +70℃
Cool chamber：0℃ salt water
The EV battery performs cold and heat shocks between the hot room and cold room.
IPX9K Water Spray Test
Test Standard: LV124
This test shall be carried out in accordance with ISO 20653 with the following parameters:
Operating mode of DUT | Operating mode II.a |
Required degree of protection | IPX9K |
Water pressure | The steam jet shall have a minimum pressure of 10000 kpa (100 bar) as measured directly at the nozzle |
Water temperature | 80 ℃ |
Test procedure | The DUT shall be subjected to the water jet from every freely accessible direction around the vehicle |
Number of DUTs | 6 |
IPX0 to IPX6K Water Splash Test
Test Standard: LV124
This test shall be carried out in accordance with ISO 20653 with the following parameters:
Operating mode of DUT | Intermitting between 1 min operating mode II.a and 1min operating mode II.c |
Required degree of protection | As specified in the component requirement specification |
Dust Test
Test Standard: LV124
This test shall be carried out in accordance with ISO 20653 with the following parameters
Operating mode of DUT | For electric/electronic components: Operating mode II.a For mechartronic components (e.g for components with fan): Intermitting between operating mode II.c and operating mode II.a |
Degree of protection to be achieved | As specified in the component Requirement Specification |
Numbers of DUTs | 6 |
Thermal Shock (Without housing)
Test Standard: LV124
Operating mode of DUT | Operating mode I.a |
Lower temperature | T(min) |
Upper temperature | T(max) |
Holding time at upper/lower temperature | 15min following attainment of complete thermal equilibrium |
Transition time | ≤10s |
Number of cycles | 300 |
Number of DUTs | 6 electronice assemblises |
Corrosion test with flow of mixed gas
Test Standard: LV124
This test shall be carried out in accordance with DIN EN 60068-2-60 Method 4 with the following parameters:
Operating mode of DUT | Operating mode I.b | |
Temperature | T(RT) | |
Humidity | 75% | |
Corrosive gas concentration | So2 | 0.2ppm |
H2S | 0.01ppm | |
No2 | 0.2ppm | |
Cl2 | 0.01ppm | |
Test duration | 21 days | |
Number of DUTs | 6 | |
