Post on 12-Aug-2020
Battery Testing Solutions.Wesley Witteveen – Weiss Technik B.V. Tiel
Weiss Technik Battery Testing Solutions.
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Future Visions with Batteries.
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Future Visions with Batteries.
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Future Visions with Batteries.
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Future Visions with Batteries.
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Future Visions with Batteries.
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Requirements on energy storages.
✓ Long duration.. Much power..
✓ Rechargeable
✓ Fast charging!
✓ Light
✓ Small
✓ Long Lifecyle / infinite number of rechargeability
✓ No heat development
✓ Long-term warehousing (with no further checks)
✓Weather-resistant (Warm, Cold, moisture, …)
✓ Low price
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Many different chemical combinations:
Which one is the best?
It always depends on your application…
Most popular in media worldwide is Li Ion.
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Highest requirements lead to a higher failure risk.
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Highest requirements lead to a higher failure risk.
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Mistakes and dangers with energy storages.
Top 3 most done mistakes with batteries:
• Too long in stock (with no control)
• Stock in wrong environmental conditions (Temperature, Humidity)
• Wrong charging (wrong charger, charging process, charging time)
Top 3 most dangerous mistakes with batteries:
• Overload or wrong loading
• Mechanical damage
• OverheatingNo chance for not testing...
(Only Li-Ion batteries have over 40 different test specifications)
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Several Test Categories for Li-Ion Batteries.
Humidity
Temperature
Thermal-Shock
Temp.-Changes
Vibration
Gas
Saltspray / Corrosion
…
Visual Inspection
Leakage
Connectors
Geometry
Weight
…
ElectricalTests
Capacity, Power, Resistence
Lifetime
Self discharge
Cold start
Safety
Short circuit
Power interrupt
Plug interrupt
Reset
Abusetests
Bruise / Squashing
Fall
Deep discharge
Overload
Reversed Polarity
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Necessary Security Topics.
Batteries with high energy level und huge performance level.
→ Potential dangers during test processes are increasing dramatically.
Safety First with test systems:
1) People
2) Buildings
Different possibilities and opinions regarding the security installations:
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Without Security Installations:
Advantages
• Lower investment / costs
• Possible damage of test equipment is accepted / acceptable
• Let the test equipment burn down and buy a new one
Disadvantages
• Environmental harms
• Stop of company processes / possible lost of money
• Maybe lost of important and expensive prototypes
• Danger for workers in the test area
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Energy Storage Checklist
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With Security Installations: EUCAR Hazard Level
Hazard Level
Description Security Level and results
0 No effects. No effect, no functional limitation
1 Start of passive security system.
No damage, no leakage, no gas leak, no fire, no explosion, no reaction, no thermal runaway.
Cell broken reversible, repairs of security installations necessary.
2 Damage No leakage, no gas leak, no fire, no explosion, no reaction, no thermal runaway.
Cell broken irreversible, repairs of security installations necessary.
3 Leakage
(Weight loss < 50%)
No gas leak, no fire, no explosion.
Leakage of electrolyte <50%.
4 Gas leakage
(Weight loss > 50%)
No fire, no explosion.
Leakage of electrolyte >50%.
5 Fire No explosion, no flying parts.
6 Fraction No explosion, but flying parts of the active mass.
7 Explosion Decomposition of battery cell.
External influences, internal topics with results on the Li-Ion battery
With Security Installations: EUCAR Hazard Level
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Test Equipment INDOOR or OUTDOOR
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Indoor• Security installation on the building in some cases
necessary
• Personal protection has to be guaranteed
• Necessary approval procedures
• Security to other facilities in the neighborhood has
to be clarified
• Existing space can be used.
07.02.2020 Weiss Battery Testing Solutions
Test Equipment INDOOR or OUTDOOR
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Outdoor• Container, bunker, seperat building etc.
• Security installations only focused on this
• Easier and faster approval processes
• Shorter installation time in many cases
• Laws of fire protection are easer in realization
• Disadvantage: Need more space…
07.02.2020 Weiss Battery Testing Solutions
Customized test equipment for batteries
¬ Customized, tailor-made complete solutions
for testing Li-Ion batteries
¬ Lots of application solutions
¬ Hazard-Level security levels
Branch: Electronics & Automotive – Li-Ion
Feature
¬ Risk of deflagration, explosion etc.
¬ Leakage of harmful gases
Test Equipment in all sizes.
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These customers use our battery testing solutions:
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Customized test equipment for batteries
¬ Customized, tailor-made complete solutions
for testing Li-Ion batteries
¬ Lots of application solutions
¬ Hazard-Level security levels
Branch: Electronics & Automotive – Li-Ion
Feature
¬ Risk of deflagration, explosion etc.
¬ Leakage of harmful gases
Test Equipment in all sizes.
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Our huge experiences: Project Examples
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• Prototype Testing (Temperature cycles)• 12 Cells in one chamber• Cell size of 200-400mm length, 20mm
depth• Central master control→ no control
panel on the chambers
Our huge experiences: Project Examples
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2-Level installation
Power electronics / Battery tester
Exhaust air with smoke detection
Kratzer control unit
Touch panel with special customer user interface
Weiss technik chamber ClimeEvent withHazard Level
Our huge experiences: Project Examples
26Plumm; Gotthardt // Battery Testing: Weiss References
Temperature chamber with 4 drawers Fully filled tray in test space
Drawer with 3 customized connection ports – One Wire ID
For internal trainings only!
Our huge experiences: Project Examples
27Plumm; Gotthardt // Battery Testing: Weiss References
• Testing unit for smaller cells
Our huge experiences: Project Examples
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• Temp. Testing for whole systems
• About 2.5m weidth
• Chamber size 6-9m2
• No big height needed
Our huge experiences: Project Examples
29Plumm; Gotthardt // Battery Testing: Weiss References
• Lift truck used for bringing packages in
• Double bottom
• Cables layed in lower level
• Temp. and Humidity testing
Our huge experiences: Project Examples
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• Temp. and Humidity
• Chamber size between 6 and 9 m2
• CO and O2 controlled
• Hazard Level 7
Our huge experiences: Project Examples
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• System is in a container outside
• Gas sensors with two switching thresholds:
• Pre-alarm activates exhaust air
• Main alarm calls fire department
Our huge experiences: Project Examples
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• Cooperation for Battery + Control unit
• Hazard Level Container with standard chambers
• HL7
• 6 Chambers (3x 600l; 3x 1500l)
Our huge experiences: Project Examples
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• Water in- and outlet
• 22 Bar flooding with water
Our huge experiences: Project Examples
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• Battery X-Ray solution
• First of its kind during temp. cycles..
2700 liter climatic chamber HL 6
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2700 liter climatic chamber HL 6
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2700 liter climatic chamber HL 6 Interior
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Gas detection
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Pressure resistant cableports
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Nitrogen purging
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Burst disc
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Cable penetrations
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Chamber 16 m3 HL 6
Optic and acoustic alarm
Pressure release flap
Fire detection via CO gas sensor
Gas and pressure resistant syphon
InertisationAccess ports with retaining clamps
Air purging unit
Burst Disc
Electrical door lock
A 3-Axis Vibration System is also called Multi-Axial Simulation Table or short: MAST system.
3-Axis Vibration System
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Possibilities for installation of a MAST system to a climatic test bench:
3-Axis Vibration System
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Test chamber with integrated MAST systemhas a flexible sealing at the actuators and
the hydraulic cylinders are positioned outsideof the chamber
Test system with flexible wall elementsincl. motor-driven raise and sink of the wall
Questions ?
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Weiss Umwelttechnik GmbHGreizer Straße 41 - 4935447 Reiskirchen ¬ GermanyTel +49 6408 84-0info@wut.comwww.weiss-technik.info