Vibration and shock test

Example

Use in Lemonergy

Record specimen, state, instrument, temperature and timing.

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Abuse testing

Deliberately driving cells and packs beyond their limits — overcharge, crush, nail penetration, external short, heating, drop — to see how they fail. Standards define each test and rank the outcome on a hazard scale from no effect to explosion.

ISO 12405

The international standard for testing lithium-ion battery packs and systems in electric vehicles, covering performance, reliability and abuse at pack level. Part 4 is the current performance specification.

Power spectral density

The way a random vibration profile is specified: acceleration intensity per unit frequency, in g²/Hz, across a band such as 5–200 Hz. The square root of the area under the curve gives the overall level in g rms. SAE J2380 and ISO 12405 use PSD profiles to stand for road vibration, whereas UN 38.3 uses a sine sweep.

Thermal shock and cycling test

Moving a cell or pack rapidly between temperature extremes, typically −40 °C and +60 to +85 °C, for many cycles, to find seals, welds and housings that fail by differential expansion. It is in UN 38.3, R100 and most pack specifications.

UN 38.3

The United Nations test sequence that every lithium cell and battery must pass before it can be shipped: altitude, thermal cycling, vibration, shock, external short, impact or crush, overcharge and forced discharge. Air shipment of cells also caps state of charge at 30 %.

R100 Part II

The part of UN R100 that tests the battery system as a unit: vibration, thermal shock and cycling, mechanical shock and crash impact, fire resistance, external short circuit, overcharge and over-discharge protection, over-temperature protection and, from the 03 series, thermal propagation. Each test ends with a check that there is no fire, explosion, electrolyte leakage or loss of isolation.

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. Battery Test Manual For Electric Vehicles, Revision 3

   Jon P. Christopherson · Idaho National Laboratory · 2015

   Topic background · Performance characterization, pulse resistance/power, life testing and reference performance tests; historical 2015 edition.