Abuse testing

Example

Use in Lemonergy

Connect mechanisms with appropriate test evidence.

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Crush test

Deforming a cell or pack between a platen and a round bar or sphere until the voltage drops or a set force is reached, to reproduce a crash. It checks whether the case and separator fail gracefully or cause a short.

Hazard level

A scale, 0 to 7, for grading the outcome of an abuse test: from no effect through leakage, venting and fire to rupture and explosion. Vehicle programmes typically require that no cell test exceed level 4, venting without flame.

Nail penetration test

Driving a steel nail through a charged cell to create a sudden internal short circuit. It is easy to run and widely cited, but its severity depends on nail size, speed and depth, and it is a poor stand-in for the small latent shorts that cause field failures.

Oven test

Heating a charged cell in an oven, typically at 5 °C/min to a set temperature such as the 130 °C of IEC 62133, and holding it there to check that it survives without fire or explosion. Hot-box variants keep heating until thermal runaway, showing how much margin the separator and chemistry provide.

Overcharge test

Charging a cell past its upper cutoff, often to 150–200 % of nominal capacity or a fixed voltage, with protection disabled. It shows how much margin the cell has above its window and whether the vent or CID acts before runaway.

External short-circuit test

Connecting a charged cell’s terminals through a resistance of a few milliohms and recording temperature and outcome. The result depends as much on the cell’s own resistance and its protective devices as on its chemistry.

References & further reading

Further reading on this topic

These sources provide broader context; they are not presented as citations for every statement in this entry.

1. Thermal runaway mechanism of lithium ion battery for electric vehicles: A review

   Xuning Feng et al. · Energy Storage Materials · 2018

   Topic background · Electrical, mechanical and thermal abuse; thermal-runaway mechanisms and propagation.